Igc 13 82

IGC
Industrial Gases Committee
IGC 13/82 The Transportation and Distribution of Oxygen by Pipeline Part 1 : Introduction and General
The Transportation and Distribution of Oxygen by Pipeline Part 1 : Introduction and General
IGC 13/82/E
Recommendations for the Design, Construction, Operation and Maintenance
32, Bd de la Chapelle 75880 PARIS CEDEX 18 The information furnished by the Association was gathered with the greatest care, and the knowledge available on the date of issue. It does not include any warranties of the Association, whose responsibility does not substitute the responsibility of the user.
Prepared by Working Group WG "C" L. Bothoel W. Busch A. de Lorenzo K.R. Mathison G.W. Randle D.H. Rowe E. Wolfe H. Zcepuck M. Jamault A.L. Linde A.L. AGA BOC A.P. Linde M.G. TS-IGC
1982
Reproduced in IMSS with permission
Page 1 of 39
IGC
INTRODUCTION....................................................................................................................................................................5 SECTION 1: GENERAL.......................................................................................................................................................6 1.1 DEFINITIONS..........................................................................................................................................................6 1.1.1 General..................................................................................................................................................................6 1.1.2 Scope......................................................................................................................................................................6 1.1.3 Pressure.................................................................................................................................................................6
1.1.3.1 1.1.3.2 1.1.3.3 1.1.3.4 1.1.3.5 1.1.3.6 1.1.3.7 1.1.3.8 1.1.3.9 1.1.3.10 1.1.3.11 1.1.3.12 Pressure range ................................................................................................................................................6 Nominal pressure ...........................................................................................................................................9 Design pressure ..............................................................................................................................................9 Strength test pressure .....................................................................................................................................9 Leak test pressure...........................................................................................................................................9 Maximum allowable operating pressure ........................................................................................................9 Working pressure ...........................................................................................................................................9 Delivery pressure ...........................................................................................................................................9 Design pressure - customers network...........................................................................................................9 Set or lifting pressure - safety valves .............................................................................................................9 Relieving pressure - safety valves ..................................................................................................................9 Bursting pressure ............................................................................................................................................9 Design temperature ......................................................................................................................................10 Working temperature ...................................................................................................................................10 Process temperature .....................................................................................................................................10 Ambient temperature ....................................................................................................................................10
1.1.4
Temperature....................................................................................................................................................... 10
1.1.4.1 1.1.4.2 1.1.4.3 1.1.4.4
1.1.5 Corrosion........................................................................................................................................................... 10 1.2 OXYGEN CHARACTERISTICS..................................................................................................................................10 1.2.1 Physical Data.................................................................................................................................................... 10

1.2.1.1 1.2.1.2 Physical characteristics ................................................................................................................................10 Oxygen content in the atmosphere...............................................................................................................11 Combustion ..................................................................................................................................................11 Biological effect ...........................................................................................................................................11 Density in relation to air...............................................................................................................................11 Miscellaneous properties .............................................................................................................................11 Properties of liquid oxygen ..........................................................................................................................11
1.2.2
Properties........................................................................................................................................................... 11
1.2.2.1 1.2.2.2 1.2.2.3 1.2.2.4 1.2.2.5
1.2.3 Industrial Oxygen............................................................................................................................................. 11 1.3 FLAMMABILITY - CONDITIONS..............................................................................................................................11 1.3.1 Flammability of Materials and Products in Oxygen .................................................................................. 12
1.3.1.1 1.3.1.2 1.3.1.3 1.3.1.4 1.3.1.5 1.3.1.6 General.........................................................................................................................................................12 Compatibility tests .......................................................................................................................................12 Ignition temperature .....................................................................................................................................12 Cleanliness ...................................................................................................................................................13 Velocity ........................................................................................................................................................13 Influencing factors .......................................................................................................................................13
1.3.1.6.1 1.3.1.6.2 1.3.1.6.3 1.3.1.6.4 1.3.1.6.5 1.3.1.6.6 1.3.1.6.7

1.3.1.7
Pressure..................................................................................................................................................13 Temperature...........................................................................................................................................14 Simultaneous effect: velocity, pressure, temperature.....................................................................14 Humidity................................................................................................................................................15 Concentration........................................................................................................................................15 Surface to volume ratio of materials .................................................................................................15 Other parameters ..................................................................................................................................16
General Combustion Process .......................................................................................................................16 General.........................................................................................................................................................19 Influencing Factors ......................................................................................................................................19
1.3.2
Ignition in an Oxygen-Enriched Atmosphere .............................................................................................. 19 1.3.2.2.1 1.3.2.2.2 1.3.2.2.3 1.3.2.2.4 Oxygen concentration .........................................................................................................................19 Pressure..................................................................................................................................................19 Fabrics - materials and treatment.......................................................................................................19 Cleanliness............................................................................................................................................20
1.3.2.1 1.3.2.2
1.3.2.3
Safety limits of oxygen concentrations........................................................................................................20
1982
Page 2 of 39
IGC
1.3.3
1.3.3.1 1.3.3.2 1.3.3.3
Combustion and Explosion of Gases and Vapours..................................................................................... 20

General.........................................................................................................................................................20 Conditions for Ignition.................................................................................................................................21 Definitions and Characteristics ....................................................................................................................21
1.3.3.3.1 1.3.3.3.2 1.3.3.3.3 1.3.3.3.4 1.3.3.3.5

1.3.3.4
Limit of flammability ..........................................................................................................................21 Minimum ignition energy...................................................................................................................22 Ignition temperature.............................................................................................................................22 Combustion rate ...................................................................................................................................22 Pressure developed ..............................................................................................................................23 Effects of pressure ...............................................................................................................................23 Effect of temperature ...........................................................................................................................24 Effect of an inert gas............................................................................................................................24 Other effects..........................................................................................................................................25
Influencing Factors ......................................................................................................................................23
1.3.3.4.1 1.3.3.4.2 1.3.3.4.3 1.3.3.4.4

1.3.3.5
Self-Ignition .................................................................................................................................................25 Nature of risks ..............................................................................................................................................26 Effect of oxygen enrichment........................................................................................................................26 Physiological effects of oxygen deficiency .................................................................................................26 Thresholds....................................................................................................................................................27
1.3.4
Physiological Risks.......................................................................................................................................... 26
1.3.4.1 1.3.4.2 1.3.4.3 1.3.4.4
1.4 CAUSES OF A CCIDENTS..........................................................................................................................................28 1.4.0 General............................................................................................................................................................... 28 1.4.1 Internal Spontaneous Ignition........................................................................................................................ 28 1.4.2 Causes of Internal Ignition ............................................................................................................................. 28
1.4.2.1 Physical/mechanical phenomena .................................................................................................................28
1.4.2.1.1 1.4.2.1.2 1.4.2.1.3 1.4.2.1.4 1.4.2.1.5 1.4.2.1.6 1.4.2.1.7

1.4.2.2 1.4.2.3
Friction of particles or foreign bodies ..............................................................................................28 Impact and incrustation of particles ..................................................................................................29 Abnormal or accidental friction within components .....................................................................29 Vibration................................................................................................................................................29 Fractures ................................................................................................................................................29 Adiabatic compression........................................................................................................................29 Thermodynamic phenomena ..............................................................................................................29
Chemical Phenomena...................................................................................................................................30 Electrical Phenomena...................................................................................................................................30
1.4.2.2.1 Exothermic phenomena.......................................................................................................................30 1.4.2.3.1 Heating due to electric currents .........................................................................................................30 1.4.2.3.2 Electrostatic charges............................................................................................................................30 1.4.2.3.3 Dust concentration...............................................................................................................................30 1.4.2.3.4 Electrolytic phenomena.......................................................................................................................30 1.4.3 Factors Influencing Ignition........................................................................................................................... 30
1.4.3.1 1.4.3.2 1.4.3.3 1.4.3.4 1.4.3.5 1.4.3.6 1.4.3.7 Lack of cleanliness.......................................................................................................................................30 Abnormally high velocity ............................................................................................................................30 Incompatible or unsuitable materials ...........................................................................................................30 Temporary connections to other networks ...................................................................................................31 Mechanical accidents on installations..........................................................................................................31 Poor workmanship & maintenance ..............................................................................................................31 Unauthorised action .....................................................................................................................................31 Mechanical damage......................................................................................................................................31 Thermal Effects ............................................................................................................................................32 Corrosion......................................................................................................................................................32 Proximity of high tension electric cables .....................................................................................................32 Natural Causes .............................................................................................................................................33
1.4.4
External Causes of Accidents......................................................................................................................... 31
1.4.4.1 1.4.4.2 1.4.4.3 1.4.4.4 1.4.4.5
1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 1.4.11 1.4.12

1982
Internal Explosions in Pipelines .................................................................................................................... 33 Oxygen - Enriched Atmosphere...................................................................................................................... 33 Explosive Atmospheres.................................................................................................................................... 34 Oxygen Deficient Atmosphere ........................................................................................................................ 34 Normal Electrical Dangers............................................................................................................................. 34 Points Where Accidents May Occur........................................................................................................... 34 Circumstances of Accidents......................................................................................................................... 34 Synoptic Table................................................................................................................................................ 35
Reproduced in IMSS with permission Page 3 of 39
IGC
1.5 REGULATIONS.....................................................................................................................................................36 1.5.1 Official Regulations and Recommendations................................................................................................ 36 1.5.2 Scope of Official Regulations......................................................................................................................... 36 1.5.3 Environmental Problems................................................................................................................................. 37 1.5.4 Dominance of Local Law................................................................................................................................. 37 1.6 GUIDANCE FOR THE PREVENTION OF, PROTECTION A GAINST , AND M EANS OF COMBATING A CCIDENTS37 1.6.0 General............................................................................................................................................................... 37 1.6.1 Prevention.......................................................................................................................................................... 37
1.6.1.1 1.6.1.2 1.6.1.3 1.6.1.4 1.6.1.5 1.6.1.6 For the whole ...............................................................................................................................................37 For the equipment ........................................................................................................................................37 For materials ................................................................................................................................................37 For the installations......................................................................................................................................37 For work on the installations........................................................................................................................38 Protection gainst third parties ......................................................................................................................38
1.6.2 Protection of Persons....................................................................................................................................... 38 1.6.3 Combating Accidents ....................................................................................................................................... 38 1.7 INSPECTION OF EQUIPMENT AND INSTALLATIONS .............................................................................................39 1.7.1 The Need for Inspection................................................................................................................................... 39 1.7.2 Inspection........................................................................................................................................................... 39
1.7.2.1 1.7.2.2 Scope ............................................................................................................................................................39 Application...................................................................................................................................................39
1.7.3
Training of Personnel...................................................................................................................................... 39
1982
Page 4 of 39
IGC
INTRODUCTION
For several years, transport and distribution of products by pipeline have developed world-wide, mainly for gaseous fuels and petroleum products. Now this system of distributions is used extensively for oxygen, especially in areas where industry is heavily concentrated. From production centres, oxygen is piped to steel mills, chemical and petrochemical plant as well as to other industrial facilities. Oxygen is not a fuel but a supporter of combustion. In oxygen or even in air which is only slightly oxygen enriched, fuels ignite more easily and burn more readily. The Companies who belong to the Industrial Gas Committee have prepared this document with a view to preventing incidents during operation of oxygen piping systems caused in particular by the phenomena known as self-ignition and to limit the impact of possible consequences. The recommendations formulated in this document are the result of many years experience in the design, installation and operation of oxygen pipelines. Application of these recommendations will ensure a high level of safety. The recommendations apply to normal operating conditions and would have to be adapted or modified if conditions deviate from normal. The document is not a manual for pipeline designers nor will it relieve manufacturers from the need to exercise sound engineering judgement in selecting materials or making decisions. The document should not be considered as an account of research work or as scientific report. Explanatory notes and comments which usually accompany the latter will only be found in this document to a limited extent. The recommendations reflect what is currently considered as the state of the art of gas pipeline design, construction and operation and the document is only a reminder of the essential aspects. The recommendations are only to be used as a compliment to National rules and regulations which remain predominant. Design may be improved with technological advances. The Industrial Gas Committee feel that it has a duty to publish such developments and will be quite prepared to examine and consider relevant remarks or suggestions which may be submitted.
TERMS OF REFERENCE
The recommendation of the Code concerns the design, construction, operation and maintenance of oxygen transportation and distribution pipeline installations, excluding production plant pipework and consumer points of use. Scope Pressure Temperature Purity 0 to 70 bar gauge -30C to +80C Higher than 90% oxygen
1982
Page 5 of 39
IGC
SECTION 1: GENERAL
1.1
1.1.1
DEFINITIONS
General
In diagrams Figure 1 and Figure 2 are shown the parts which make up a pipeline network and their principal definitions. The document deals with distribution networks from the supply stations of oxygen plants to the distribution stations at customers works. (Points A to B, Fig. I). It does not deal with the other parts of a complete network. oxygen plants distribution piping in the workshops points of use
1.1.2
Scope
This documents deals with the distribution of oxygen with purity in excess of 90%, at a pressure higher than 1 bar and having a dew point lower than -30C at the maximum operating pressure at temperatures between -30C and +80C.
1.1.3
1.1.3.1
Pressure
Pressure range Gaseous oxygen is transported under pressure. The pressure provides the energy for transportation. In the case of oxygen pipelines 3 pressure ranges may be distinguished (pressure unit: bar gauge): 0-25 bar : generally used for distribution in workshops. (see I.C.C. Code) 1-70 bar : DELIVERY NETWORKS (Tolerance +10%) the subject of the present document. above 70 bar : special constructions outside traditional standards, not covered by this code.
1982
Page 6 of 39
IGC
1982
Page 7 of 39
IGC
1982
Page 8 of 39
IGC
1.1.3.2
Nominal pressure The nominal pressure defines the maximum allowable pressure for a given basic temperature: at which a fitting or system may be operated according to a given code. Design pressure The design pressure is the maximum pressure for which the fitting or system has been calculated. For calculations additional parameters such as temperature, corrosion, cycling pressures, etc., shall taken into account as well as the maximum stresses permitted both at operational level and for testing. Strength test pressure The strength test pressure is the pressure to which the fittings or systems are subjected at the time of manufacture or before going into service. The test is generally of a statutory nature and the test pressure is defined on the basis of the design pressure increased in a defined manner by the code or official regulation applied. Leak test pressure The leak test pressure is the pressure to which a fitting or system is subjected when a leak test is made separately from the strength test. The value for it is defined by the constructors own rules or by the code or regulation applied. Maximum allowable operating pressure The maximum allowable operating pressure is the maximum pressure that a fitting or system is able to sustain at a given temperature in order to meet the requirements of a given code. It shall not exceed the design pressure. This pressure and the test reference should be written on components after testing and checking with calculation notes. Working pressure The working pressure is the pressure under which the installations function. Delivery pressure The delivery pressure is the pressure at which the product is delivered to the customer. Design pressure - customers network The pressure used for the design of the distribution network in customer's works
1.1.3.3
1.1.3.4
1.1.3.5
1.1.3.6
1.1.3.7 1.1.3.8 1.1.3.9
1.1.3.10 Set or lifting pressure - safety valves The set pressure of a valve is the pressure at which the valve begins to open, this pressure shall not be greater than the design pressure of the installation. 1.1.3.11 Relieving pressure - safety valves The relieving pressure of a valve is the pressure at which the valve passes its rated flow. Normally this will be within 10% of set or lifting pressure. 1.1.3.12 Bursting pressure The bursting pressure of a safety bursting disc is defined as function of the design pressure of the installation. See 4.2.5.4.2. Certain codes and regulations accept destructive testing of a component as an alternative to a design calculation. The working pressure will then be the bursting pressure multiplied by a safety factor as defined by the code or regulation. This method may be used for mass produced components.
1982
Page 9 of 39
IGC
1.1.4
1.1.4.1
Temperature
Design temperature The design temperature is the temperature used in the selection of the materials and the dimensioning of the installation components considered in accordance with the code applied. In the installations concerned two design temperatures may be distinguished. The highest design temperature. This is taken into account in determining the thickness of the element considered.
The lowest design temperature which determines the selection of the materials used. The unit is the degree CELSIUS. 1.1.4.2 Working temperature The working temperature is the temperature taken into consideration in the specification of a standardised element (see 1.1.3.2.). 1.1.4.3 Process temperature The process temperature is the design temperature for the normal operation of the installation. With regard to transportation networks, in practice the temperature remains within limits which have no effect on the dimensional specification of the components. When necessary a distinction is made between: 1.1.4.4 normal operating temperature minimum operating temperature maximum operating temperature minimum allowable temperature maximum allowable temperature
Ambient temperature The ambient temperature is the outside temperature, variable at a given point as a function of the prevailing climatic conditions, the reason, the time of day or night. It may occur at two extremes: Low temperature: specification of materials as a function of brittleness: High temperature: the effect of a rise in temperature on the pressure of a gas in an enclosed space.
1.1.5
Corrosion
Dry oxygen with Characteristics defined in 1.1.2 is not corrosive. The protection of the pipeline from external corrosive agents shall be ensured.
1.2
1.2.1
1.2.1.1
Oxygen Characteristics
Physical Data
Physical characteristics Chemical formula Molecular weight Specific mass of the gas at 0C and 1.013 bar Boiling point at 1.013 bar Specific mass of the liquid at 1.013 bar and -183C O2 32
3 1.4290 kg/m
-183C 1.141 kg/1
1982
Page 10 of 39
IGC
1.2.1.2
Oxygen content in the atmosphere Oxygen is the second component by quantity in the air of the atmosphere: Oxygen Nitrogen Argon 21% by volume in the air 78% by volume in the air 0.9% by volume in the air
1.2.2
1.2.2.1
Properties
Combustion Oxygen is an oxidising gas which under certain conditions combines with almost all the elements giving rise to a brisk exothermic reaction. Compared with air, pure oxygen or oxygen enriched air favours and activates combustion, especially that of organic materials. This phenomenon is aggravated by the effects due to the pressure of the gas (higher partial pressure) or due to higher velocity (blowing effect).
1.2.2.2
Biological effect Oxygen is necessary for life. Air which is deficient in oxygen causes physiological difficulties and even asphyxia.
1.2.2.3
Density in relation to air Being slightly heavier than air (density 1.05) oxygen has a tendency, especially when cold, to accumulate at low points.
1.2.2.4
Miscellaneous properties Gaseous oxygen is odourless, colourless and tasteless. It is not toxic. In the absence of moisture it is not corrosive.
1.2.2.5
Properties of liquid oxygen By reason of its temperature liquid oxygen can make certain materials brittle. It can cause serious burns on contact with the skin.
1.2.3
Industrial Oxygen
Industrial oxygen is mainly produced from the air, from which it is extracted by distillation at low temperature (see also 1.1.2). IMPORTANT NOTE Nitrogen is also an odourless, colourless, tasteless gas. The detection of any anomoly by the senses is therefore inoperative, whether it is a matter of pure oxygen, enriched air, air deficient in oxygen, or pure nitrogen.
1.3
Flammability - Conditions
In this section the characteristics of the flammability of materials or products in oxygen or oxygenenriched atmospheres are examined. Also the physiological aspects of atmospheres enriched or deficient in oxygen. Distinction is made between : the flammability of materials or products in oxygen leading to spontaneous ignition (1.3.1) flammability in oxygen-enriched atmospheres (1.3.2) the flammability and explosivity of gas or vapour in an atmosphere of oxygen, of air, or of oxygen-enriched air (1.3.3) the physiological consequences of an atmosphere enriched or deficient in oxygen (1.3.4)
1982
Page 11 of 39
IGC
1.3.1
1.3.1.1
Flammability of Materials and Products in Oxygen

General Combustible materials, and indeed materials reputed to be non-combustible in air, may ignite more readily in oxygen. Compared with air, other considerations shall be taken into account: Ignition temperature is lower Energy required for ignition is much lower Combustion temperature is higher
Combustion rate is greater This combination of properties makes ignition easier to initiate and develop. Combustion generally progresses in the direction of the gas flow. 1.3.1.2 Compatibility tests There are a large number of tests which make it possible to select materials for use in oxygen. It is very difficult to reproduce tests which simulate the many parameters involved at the same time, and is practically impossible to reproduce actual accident conditions met with during operations. Of the tests that are best known, mention is made of the following: Determination of ignition temperature Adiabatic compression tests Determination of the oxygen index (concentration of oxygen required to maintain combustion of a material) Determination of the combustion rate Determination of acceptable velocities (ignition by friction and percussion of particles) Simulation tests
The results of these tests make it possible to classify materials within the framework of the test conditions. These results shall therefore be the subject of interpretation by specialists in order to determine their application. The ignition temperature is not the only factor to be taken into consideration. Certain other factors are capable of influencing the effect of the Ignition Temperature and are capable of accelerating or retarding ignition, especially those which have the effect of increasing or decreasing the heat input necessary to reach the ignition temperature. These various factors and parameters will now be analysed. 1.3.1.3 Ignition temperature The ignition temperature is most commonly determined by a specimen test of product whose temperature gradually rises in an enclosure under constant oxygen pressure until ignition occurs. This is known as the bomb test. In Chapter 2.0 will be found ignition temperature figures for various materials and products. The sample figures below emphasise the drop in ignition temperature in oxygen as compared with air, at atmospheric pressure. In oxygen C Mild steel Perspex Cotton Wool 1097 to 1250 430 360 500 In air C 1227 to 1277 595 465 > 600
1982
Page 12 of 39
IGC
1.3.1.4
Cleanliness As repeated numerous times, the cleanliness of the gas pipeline is an important safety factor. The gas is manufactured clean, however dust may be carried from the installations. The causes of accidents are dealt with in 1.4 and the problems of cleanliness are dealt with in 2.3. Velocity The velocity of the gas acts as the motive element for particles, which may in certain cases as a result of friction and percussion attain temperatures of a kind to initiate ignition. The velocity in certain countries has for many years been limited to 8 m/s, whatever the conditions of use. In the meantime tests and operational results have shown that this arbitrarily chosen velocity has been safely exceeded. Tests have shown that in steel pipelines the friction of particles in the networks cannot cause ignition unless the oxygen attains a velocity in excess of 60 m/s, and then only after or during changes in direction of flow. It will therefore be possible in most cases to allow velocities higher than 8 m/s in correctly constructed steel pipelines. The same applies to installations maintained in a clean condition. It should however be emphasised particularly for long lengths of pipeline, that the level of pressure drop to be complied with generally has the effect of limiting the velocity to a safe value. Recommended maximum velocities are indicated in 4.1.2.
1.3.1.5
1.3.1.6 1.3.1.6.1
Influencing factors Pressure An increase in pressure results in : lowering of the ignition temperature increasing the combustion rate
Within the limits set for this Code, however, any increase of pressure beyond 30 bar has little effect on the ignition temperature and combustion rate. The curves in Figure 3 show the temperature at which ignition takes place and of the combustion rate as a function of pressure.
1982
Page 13 of 39
IGC
Figure 3 : Ignition temperatures and combustion rates as a function of pressure
Increase in pressure also has the effect of increasing the dynamic pressure and the density and therefore the capacity for entraining particles, for same gas velocity. The effect of a rupture may increase with an increase in pressure and pipe diameter. 1.3.1.6.2 Temperature High temperature of the oxygen, and at the same time that of the pipelines and components favours ignition. The main factors that favour ignition following an increase in temperature are: The energy required to reach the ignition point is less The combustion rate is higher Less heat removed by the gas flow
Particles subjected to friction reach their ignition point more easily Similarly in the case of adiabatic compression the compression ratio necessary in order to obtain a given temperature will be less as the initial temperature is higher. Starting from 1 bar(a) the compression ratio required in order to pass from 15 to 400C is 20, but is only 7 in order to pass from 130 to 400C. 1.3.1.6.3 Simultaneous effect: velocity, pressure, temperature The tendency towards ignition by entrained particles increases with : increase in oxygen velocity increase in oxygen pressure
rise in oxygen temperature The graph fig.4 shows qualitivly through the results of a test the interrelationship of pressure and temp. on the velocity to cause ignition.
1982
Page 14 of 39
IGC
Figure 4 : Ignition as a function of velocity, pressure and temperature
1.3.1.6.4
Humidity It is probable that ignition is favoured in the presence of dry gas, although this is difficult to assess. On the other hand humidity may cause corrosion with the disadvantage of component damage, entrained particles etc. It is possible that in certain cases humidity may influence the accumulation of electrostatic charges. Phenomena in this field is still insufficiently known and generally speaking we have only hypotheses which have not been investigated. Industrial oxygen is today a dry product and therefore we need not under normal conditions of working fear any effects due to the humidity content.
1.3.1.6.5
Concentration This Code deals with the distribution of oxygen on a concentration equal to or greater than 90%. The effect of oxygen enrichment is dealt with in 1.3.2. Surface to volume ratio of materials Ease of ignition of a material depends upon the area in contact with oxygen. For example a cube of 1 cm in size presents an area of 6 cm2 , while the same cube divided into cubes of 0.1 cm has a surface area of 600 cm2 . It may be said that the more finely divided a material is, or the more it lacks compactness : the smaller the beat addition necessary to initiate combustion because of the smaller heat absorbtion and lower dispersion ability.
1.3.1.6.6
the faster will be the reaction combustion rate, because of the greater surface area of attack for a given mass. This is emphasised by the curves in Figure 3, the rate being higher for the 1 mm diameter wire than for the 2 mm. These considerations will require limitations in the use of liquids, pastes, powders, fabric and material of small mass.
1982
Page 15 of 39
IGC
1.3.1.6.7
Other parameters Many other parameters also enter into consideration in defining the liability to ignite. (a) Physical and Chemical characteristics of the material Metal hardness, impact behaviour, ability to produce sparks. Thermal conductivity Good conductivity favours the dispersion of heat while poor conductivity favours the concentration and rise of temperature. Specific heat High specific heat retards the rise of temperature Heat of combustion or of reaction A high value increases the amount of heat available Presence of a film of oxide.
(b)
Oxides retard ignition. This may be the case for metals either in the solid or liquid state to the point of preventing the propagation of ignition in a stable environment. Transformation by ageing Certain materials such as polyurethane burn much more easily after ageing. Retarding or accelerating effect of materials. Design of parts Configuration Sharp edges favour initiation of ignition Mass or thickness of parts Capacity for absorbing heat
(c)
Loose Parts A loose part is more liable to store heat, especially if it is small and a poor conductor, hence the necessity for plastic parts to be in intimate contact with the metallic materials.
1.3.1.7
General Combustion Process Spontaneous ignition is generally speaking a phenomenon. The development of which is not always easy to explain. Ignition generally begins in materials which ignite easily. These may be materials forming part of components, or deposits of foreign matters. There may also be a latent source of ignition in a very low flow of oxygen or in stationary oxygen, this may develop suddenly when significant flow is established. Ignition is propagated from material to material according to the characteristics of the system. On the other hand as combustion depends on heating and maintaining the components at the reaction temperature, a very large flow of oxygen at high velocity may disperse the combustion products and cool the reaction zone sufficiently to stop combustion. One thing is certain : When combustion spreads externally everything then happens very quickly and may result in damage. According to circumstances the effects upon the component which initiated ignition may : (a) be limited to internal combustion without perforation. In this case damage is slight and limited to the component concerned without consequence for the environment. (b) cause perforation of small dimensions with a jet of oxygen and of an incandescent material. In this case, too, the damage is generally small and limited in the path of any projections.
1982
Page 16 of 39
IGC
(c)
cause extensive combustion of the installation or the component (generally downstream), causing : large scale projections of : incandescent or molten particles incandescent large pieces large pieces of broken metal
(d)
oxygen enrichment of the area resultant bursting caused by deterioration of the mechanical properties due to reduction of thickness, or heating, when the enclosing walls can no longer resist the pressure of the gas.
Bursting may be caused by : (a) Reduction of wall thickness : (b) metal partly burnt away erosion by internal combustion of elements by combustion of the metal itself
Heating :
by the flow of molten oxides and metal along the bottom of a pipe. In cases (c) & (d) and sometimes case (b) the consequences may be aggravated by the effect of the jet action of the escaping gas. This may lead to the violet displacement of pipes which may cause damage to the surroundings. In conclusion we may recall that in order for igntion to develop into an accident there shall be 4 conditions. the presence of oxygen the source of ignition a material which is combustible under the effect of the ignition source conditions favourable for the development of combustion
Ignition and combustion conditions are shown in Table I. This table also applies for 1.3.2 and 1.3.3.
1982
Page 17 of 39
IGC
Table 1 : Oxygen Installations conditions for ignition and its effects
1982
Page 18 of 39
IGC
1.3.2
1.3.2.1
Ignition in an Oxygen-Enriched Atmosphere

General The behaviour of materials flammable in air containing 21% oxygen changes as soon as the proportion of oxygen exceeds this concentration. Any excess of oxygen in the air has a considerable effect on combustion. The curves in Figure 5 illustrate the effects of enrichment on materials currently used in the manufacture of clothing. Figure 5 : Ignition temperatures and combustion rates as a function of oxygen concentration
It is possible to classify materials according to an oxygen index, which is the percentage oxygen below which combustion cannot be maintained under clearly defined test conditions. The enrichment of air with oxygen makes combustion more likely, brighter, hotter and more rapid. We shall briefly analyse the effect of the various parameters, relative to the protection of persons. 1.3.2.2 1.3.2.2.1 Influencing Factors Oxygen concentration Fabrics which on receiving a certain amount of ignition energy (a spark) do not ignite in air may ignite very rapidly when the oxygen concentration is increased. The increase in oxygen concentration accelerates combustion (see Figure 5) for the following reason : 1.3.2.2.2 Energy required for ignition is much lower increase in the temperature of combustion rapid increase of the combustion rate
See 1.3.2.3 for safety limits. Pressure Accidents that occur in the atmosphere as a result of enrichment are not affected by pressure. However, the danger increases rapidly with pressure. Fabrics - materials and treatment Some fabrics are more flammable than others. Wool has a greater resistance to fire than cotton or linen. Closely woven fabrics are generally more resistant to fire. Some synthetic materials offer a certain resistance to fire but may cause serious burns by melting and clinging to the skin, therefore are not recommended. Fabrics impregnated with fire-resistant products reputed to be difficult to burn in air burn more readily in higher oxygen concentrations. It should also be noted that washing reduces the efficiency of impregnation.
1.3.2.2.3
1982
Page 19 of 39
IGC
1.3.2.2.4
Cleanliness A garment stained or impregnated with oil, grease or hydrocarbons ignites more easily and burns more rapidly. Safety limits of oxygen concentrations It is difficult to establish a rigid threshold. It may however be considered that the danger is great as from 25%. Various factors may however influence ignition, as we have seen in 1.3.2.2. In addition, the degree of oxygen enrichment may : be variable from one point to another increase progressively or suddenly
1.3.2.3
vary as a function of gaseous mass displacement For these reasons, working in an oxygen-enriched atmosphere is prohibited, and warning shall be given as soon as the oxygen concentration exceeds 22%. (see 6.1.2.1). The general problem of prevention will be dealt with in 1.6 of the Code which deals with work on pipeline networks. Protection and action to be taken are dealt with in section 7 of the Code.
1.3.3
Combustion and Explosion of Gases and Vapours

This section is concerned with the dangers of explosive mixtures. The installations covered by this Code are not designed to carry such mixtures normally. These mixtures can only be introduced accidentally. It should be noted that normal pressure release devices are not sufficient to limit the effect of explosions. It nevertheless seems advisable to explain the nature of the dangers to impress upon personnel the necessity for preventing the formation of such mixtures within systems as well as areas of installation or maintenance work.
1.3.3.1
General Flammable gases are capable of reacting violently with oxygen, whether with oxygen or oxygenenriched air or air. The oxygen acts as a supporter of combustion. Ignition starts the reaction and combustion is the development that follows. The combustible nature of these gases can create dangers of fire or explosion in the event of mixing with oxygen or air. An explosion may result in considerable damage in the event of bursting of the enclosure in which ignition occurs. Explosion may also occur in the atmosphere. The existence of a dangerous mixture of combustible gases or vapours is always accidental and may arise for example : from a back flow of gas from a point of use from an incorrect connection from residues of cleaning products incompletely rinsed out release of other gases
from leaks in hoses or equipment, e.g. welding cutting and heating equipment Ignition of a combustible mixture may be caused by : a brief pin-point source, within the mixture, e.g. electric spark, incandescent particle, impact heating through accidental contact with a heat source or element. (Pipe or component wall, internal parts) spontaneous ignition as described in 1.3.3.5
1982
Page 20 of 39
IGC
1.3.3.2
Conditions for Ignition The following are necessary for ignition to take place : In all cases : (a) The composition of the mixture shall lie within the lower and upper limits of flammability. A mixture can ignite and its ignition can be propagated if the mixture contains a sufficient proportion of combustible gas and a sufficient proportion of air/oxygen.
In addition: (b) In the case of a pin-point source, it is necessary for the energy introduced by the source to be adequate. (c) 1.3.3.3 1.3.3.3.1 In the case of heating by contact or of spontaneous ignition, it is necessary for the ignition temperature to be reached in the mixture.
Definitions and Characteristics Limit of flammability The lower limit of flammability is the lowest concentration of combustible gas at which ignition is possible. The upper limit of flammability, is the highest concentration of combustible gas, above which ignition is not possible because the mixture is too deficient in air or oxygen. NB A mixture containing a proportion of combustible gas which exceeds the upper limit of flammability in air cannot propagate the flame within itself but it can burn in contact with the outside air with a diffusion flame. It is usual to express these limits as percentages by volume of the combustible gas and unless otherwise stated they refer to standard conditions of temperature and pressure. The limits are given for some common products in Table II for the two cases of mixture with oxygen and mixture with air. It should also be noted that most of the vapours emitted by the solvents are heavier than air and that there may be at their tendency for concentrations at low points. Table II:- Limits of flammability at 20C and 1013 mB Product Formula Self Ignition Temp C in Air 299 405 609 450 585 537 466 Flammability Limits in Vol % in Air lower 2.5 1.9 12.5 3.1 4 4.5 2.2 8 upper 81 8.5 74 32 75 15 10 12 In O2 lower 2.8 1.85 15.5 2.9 4.65 5.0 2.25 7.0 upper 93 49 93.9 79 93.9 60.5 52 64.5
Acetylene Butane Carbon monoxide Ethylene Hydrogen Methane Propane Trichloroethylene Trichloroethane Trifluorotrichloroethane Trichlomonofluromethane (Fll) Methyl ether Petroleum ether Light petrol Methyl alcohol Monoethyleneglycol (clycol)
C2 H2 C4 H10 CO C2 H4 H2 CH4 C3 H8 C2 H Cl3 C2 H3 Cl3 C2 F3 Cl3 CF Cl3 (CH3 )2 0 C5 H12 C H4 O C2 H6 O2
Non-Flammable Non-Flammable 350 3.4 246 1 230 1 464 7.3 412 3.2
18 6.5 6.5 36
3.9
61
82
1982
Page 21 of 39
IGC
1.3.3.3.2
Minimum ignition energy The minimum ignition energy is the minimum energy required to ignite a mixture. In some cases it may be very small, of the order of 0.02 millijoule in air for most flammable gases. It should be also noted that gases or vapours non-flammable in air, can burn with pure oxygen or enriched air but may react with oxygen or oxygen enriched air. Minimum ignition energy is defined for each gas, as the mixture which is most flammable under the test conditions. It may also be given as the minimum electrical current to obtain ignition referred to that for methane.
1.3.3.3.3
Ignition temperature The ignition temperature also called the temperature of self-ignition, is the lowest temperature at which a mixture may ignite under certain conditions. The minimum ignition temperature given in Tables is indicated for mixtures at atmospheric pressure. It corresponds to a mixture laying within the limits of flammability. See Table 2. The ignition temperature rises as the mixture approaches the lower or upper limit (see Figure 8) or if the inert gas content increase (Figure 7). Note: The flash point is the minimum temperature to which a flammable liquid is raised so that the vapour given off ignites in the presence of a flame, spark, etc.
1.3.3.3.4
Combustion rate Deflagration - Explosion - Detonation The progress of combustion and the destructive effect of flammable mixtures may vary widely: Deflagration and explosion : The term explosion is sometimes given a general connotation which covers both deflagrations and detonations. The propagation of the combustion of a deflagration or explosion is effected mainly by the thermal conductivity and to a lesser extent by the effects of diffusion. In a deflagration the combustion rate, particularly in the vicinity of the lower and upper limits of flammability, is of the order of a few dm/s (Approx 1 m/s). In an explosion combustion rates of several m/s (usually less than 100 m/s) are producted. Propagation velocity varies considerably as a function of the dimensions of the enclosure. Detonation: In detonation the flame propagation is supersonic. When an explosive mixture is ignited, the explosions may be converted into detonations, the reaction then being brought about by the shock wave. Detonations are also distinguished by the fact that the speed of combustion is comparatively constant. e.g. the limits of flammability of hydrogen in air. in practice, however, detonation is uncertain. EXAMPLE Figure 6 is a diagram showing the distribution of the zones for the air hydrogen mixture. The limits of flammability of hydrogen in air vary from 4 to 75% by volume. Laboratory tests conducted with pipes of less than 50 mm diameter and under certain conditions have, however, shown that detonations can only be produced with hydrogen-air mixtures between the limits from 18 to 59 vol %.
1982
Page 22 of 39
IGC
1.3.3.3.5
Pressure developed Explosive ignition generally develops a high pressure in a closed system which varies with the volume and shape of the system owing to the cooling effect of the walls. The figures given in the tables unless otherwise stated indicate starting from atmospheric pressure the mixture which gives the highest pressure under the test conditions. Up to 10 bar initial pressure the multiplying factor of the initial pressure remains approximately constant; above 10 bar it increases. When in a stabilised environment, there is deflagration after detonation, the pressure may reach : 7 times the initial pressure with air 12 times the initial pressure with oxygen
When there is detonation the pressure attained is multiplied by 2 in the stock wave and by 5 in the reflected wave. In all cases the pressures developed are much higher than the design pressure of the installations. 1.3.3.4 1.3.3.4.1 Influencing Factors Effects of pressure Small variations in atmospheric pressure have only a negligible effect on the flammability limits. On the other hand when the pressure rises there may be appreciable variations in flammability limits as shown by the figures below for methane. PERCENT BY VOLUME Methane in air in oxygen Pressure 1013 mb 100 bar 1013 mb Lower Limit 4.5 3.7 5 Upper Limit 15 56 58
100 bar 5 90 The pressure sometimes has the effect of lowering the ignition temperature, even to a considerable extent. This effect is added to the previous one, the two together acting towards the aggravation of danger. It should also be noted that with increase of pressure the results are aggravated. When the initial pressure is high the developed pressure reached is much greater and the explosive effect increases. The effect of pressure on the ignition temperature is illustrated in Figure 7.
1982
Page 23 of 39
IGC
Figure 7 : Self-ignition temperature as a function of pressure in pure oxygen (stoichiometric mixture)
1.3.3.4.2
Effect of temperature At atmospheric pressure or at a given pressure, if the temperature of a mixture rises, the lower limit is lowered slightly and the upper limit is raised. As long as 200C is not exceeded, the variation remains comparatively small, as shown by the examples below. PERCENT BY VOLUME Temp C 20 Methane in air Trichloroethane in oxygen 100 25 100 200 Lower Limit 5 4.7 6.6 5.5 4.1 57 60 Upper Limit 15 15.7
It may also be said that a high temperature facilitates ignition by reducing the amount of energy needed. 1.3.3.4.3 Effect of an inert gas In air deficient of oxygen and above a certain total concentration of nitrogen there is no possibility of ignition, whatever the ratio of fuel to oxygen. The progressive narrowing of the limits of flammability leading to complete impossibility for ignition are shown graphically in Figure 8.
1982
Page 24 of 39
IGC
Figure 8 : Flammability diagram
1.3.3.4.4
Other effects The two limits of flammability are not absolutely specific, they depend on test conditions since their values vary slightly with other factors, such as : the shape of systems the volume of systems
the intensity of the source of heat The dimensions, especially length-to-width-ratio, are important for the development of detonations. Long pipes are unfavourable in that respect. Humidity of the gas may also play a part but its influence is negligible. We may also mention the effect of the composition of the mixture on the ignition temperature according to whether a mixture is near to the lower or the upper limit and according to whether it is a mixture with air, with oxygen, or with air that is deficient or enriched. However, these various mixture possibilities have little effect upon the ignition temperature. Other parameters, more directly connected with the characteristics of the products, may clarify the development of an accident. They shall be taken into consideration either in explaining an accident or in order to specify the choice of products. Characteristics for cleaning products such as the following may be involved : difficulty of removal ease of evaporation (evaporation rate)
heat of evaporation The concentration of a mixture may also determine other characteristics which may modify dangers between one concentration and another or one product and another. 1.3.3.5 the mixture which develops the highest pressure on explosion the mixture which requires the lowest temperature for spontaneous ignition the mixture which is most incendiary, i.e. the most able to transmit ignition when started the mixture which is most inflammable, i.e. the one that requires the smallest ignition energy
Self-Ignition A mixture of flammable gas and air or oxygen which is heated may reach a temperature at which it becomes the seat of a chemical oxidation reaction. This reaction is slow at first but may grow rapidly and finally suddenly initiate ignition in the mass when the temperature of self ignition or ignition is reached. A high initial temperature favours the development of the reaction. This phenomenon is called self ignition (spontaneous ignition). It assumes an explosive nature when the temperature of ignition is reached.
1982
Page 25 of 39
IGC
The minimum ignition temperature depends upon the pressure and conditions (thickness, materials, shape and state of surface) and of the various reaction characteristics. Figure 9 shows diagrammatically for a given pressure the limits of flammability as a function of the temperature, the zone of slow reaction and the ignition temperature Figure 9 : Self-ignition: zone of slow reaction 1. Poor mixture which does not propagate the flame 2. Mixture which propagates the flame 3. Rich mixture which does not propagate the flame 4. Zone of slow reaction Li Lower limit of flammability Ls Upper limit of flammability
1.3.4
1.3.4.1
Physiological Risks
Nature of risks The main risk for personnel is that of changes in the composition of the breathing air. Oxygen is essential to maintain life and it is vital to ensure that it is present in sufficient quantities in the air breathed. Normal air contains 21% oxygen and if there is any deviation from this concentration, especially if the oxygen concentration is lowered, there may be danger. In the case of installation or maintenance of a system this danger is essentially connected with the use of nitrogen during the operation of blowing, inerting or testing.
1.3.4.2
Effect of oxygen enrichment Breathing pure oxygen is not dangerous except in the event of prolonged exposure at high concentration or under pressure.
1.3.4.3
Physiological effects of oxygen deficiency The figures given in Figure 10 are rather conservative. The values indicated are those allowed for Zones located at sea level (1013 mb). When at an altitude, these values shall be increased proportionately to the reduction of barometric pressure in order to maintain the same level of partial pressure for the oxygen. The value of 17% shall be raised from 0.20% to 0.27% per 100 metres. When increasing from 0 to 2000 metres in altitude acclimatisation allows adaptation varying according to the individual and reduction of the altitude is proportional to the decrease of partial pressure.
1982
Page 26 of 39
IGC
Figure 10 : Thresholds of Physiological Dangers
The above figures result from commonly adopted values admitted in the specialist literature. Apart from the dangers connected with the solubility of nitrogen in the blood during respiration under pressure, the danger is that of reducing the oxygen concentration and causing asphyxia. Asphyxia may develop suddenly or slowly and insidiously. In the sudden process the victim falls unconscious. A few seconds to a few minutes from entering the dangerous atmosphere suffice, according to the degree of oxygen deficiency or according to the individual. Generally, oxygen deficiency leads to a lowering of vigilance, distortion of judgement and even a sensation of well-being. As nitrogen is odourless, the danger is not readily detected. This subsequent loss of consciousness renders the victim incapable of self rescue. Exposure to pure nitrogen quickly results in death or more or less serious after-effects through irreversible damage of the cells of the brain. 1.3.4.4 Thresholds In practice it is advisable to adopt 17% as the minimum concentration of oxygen, below which it will be considered that there is danger. With regard to oxygen-enriched atmospheres there are few physiological dangers. On the other hand, as we have seen in 1.3.2, dangers of ignition increase rapidly when the normal concentration in the air is exceeded. NB For additional information refer to ICC document 876E entitled Prevention of Accidents arising from enrichment or deficiency of oxygen in the atmosphere.
1982
Page 27 of 39
IGC
1.4
1.4.0
Causes of Accidents
In this section we list the various kinds of accident and their possible causes.
General
The reader is reminded that Combustion requires the presence of three factors. Oxygen Combustible Material Means of Ignition
See Table I, 1.3.1.7. The list that follows although comparatively long does not claim to be absolutely complete.
1.4.1
Internal Spontaneous Ignition

Accidents due to internal ignition are the most typical kind of accident and its various aspects and causes are generally covered by the term spontaneous ignition. Spontaneous ignition may occur in an installation in service, at rest or being worked on (stopping, putting into service, handling, inspection, survey, maintenance, modification). Self-ignition may have serious consequences, its unexpectedness surprising and its effects sometimes violent. The ignition process is described in 1.3.1.7. The venting of large quantities of oxygen may produce an enrichment which may be the source of a new ignition in the area affected. When perforation or bursting occur in the ground or next to a building the accident may also provoke ejection of sand, earth, stones or other materials. In oxygen systems spontaneous internal ignition without external energy supply is the most typical accident. External causes can also be the origin of a spontaneous ignition of the circuit. The cause of ignition may then be the energy developed by a shock or a rupture, or the effects of velocity of the gas being vented.
1.4.2
Causes of Internal Ignition

Internal ignition is caused by any phenomenon able to impart to an element a calorific energy sufficient to provoke ignition, without addition of outside energy. The use of materials of too low ignition temperature or the presence of extraneous elements that are easily combustible may cause ignition. Various phenomena are liable to bring materials to an ignition temperature. For instance : Physical/Mechanical phenomena Chemical phenomena Electrical phenomena
1.4.2.1 1.4.2.1.1
Physical/mechanical phenomena Friction of particles or foreign bodies Caught by the flow of gas the particles become heated by friction when in contact with the walls. This possible source of heating necessitates the limitation of gas velocities. (See 4.1) However, it should be noted that the temperature of particles carried in the gas stream is very quickly lowered to that of the ambient gas.
1982
Page 28 of 39
IGC
1.4.2.1.2
Impact and incrustation of particles Similarly, when carried by the flow of gas, particles become heated on encountering an obstacle. This may have a cumulative effect. If the heated particles have become encrusted on an organic material of low thermal conductivity, a localised rise in temperature can occur. If the particles are themselves combustible, the risk is greater. Another source of heating which is an aggravating factor is the focalisation of particles which may occur at a bend. Abnormal or accidental friction within components For example : Abnormal friction on opening a valve. Friction within volumetric meters having moving parts. Vibration An organic element subjected to a high rate of vibration rises in temperature. There can be combustion only if the ignition temperature is reached before the element loses its consistency under the effect of the temperature and thus stop vibrating. Fractures In the case of a rapid fracture the temperature of the material rises in the fracture zone. The roughness of the surface of the fracture may also favour ignition by the high surface/mass ratio. In addition to fractures a noticeable temperature rise may occur with deformation due to : Elongation Flexing Shearing
1.4.2.1.3
1.4.2.1.4
1.4.2.1.5
1.4.2.1.6
Adiabatic compression The adiabatic compression of oxygen may involve local rises of temperature sufficient to cause ignition. This can occur when there is rapid pressurisation of an oxygen system. Tl and Pl being the absolute initial temperature and pressure, the temperature T2 in correlation with the final pressure P2 is determined by the following formula :
P2 T 2 = T1 P1
P2 T 1 P1
0 .28
CP = CV =
Ratio of specific heats at constant pressure and constant volume.
The curve Fig. 11 shows the rise of temperature obtained by adiabatic compression starting at 15C between 0 and 100 bars. The curve shows that this rise can be considerable, but in actual practise it is balanced by the unavoidable losses of heat. 1.4.2.1.7 Thermodynamic phenomena The flow of gases, in bodies having sectional changes and complex profiles, may form eddys. Similarly, in cul-de-sacs, metallic particles may be subjected to vibration or resonance. These may cause heating.
1982
Page 29 of 39
IGC
1.4.2.2 1.4.2.2.1
Chemical Phenomena Exothermic phenomena This phenomenon concerns easily oxidisable products whose exothermic reaction may produce a rise of temperature sufficient to initiate ignition. Ignition will be avoided by the strict selection of materials and effective cleaning. This phenomena can only occur when foreign matter in the system reacts with oxygen. Electrical Phenomena Heating due to electric currents For various reasons pipes or components can be subjected to the passage of an electric current. Parts or components can be insulated from the rest of the installation. Conductive particles are able to bridge over the insulated parts, the current passes through these particles and become heated by the Joule Effect until the point of ignition. Electric arcing can also occur. Electrostatic charges Phenomena relating to static electricity are little known in relation to oxygen systems, however electrostatic discharges cannot be excluded as a cause of ignition. in particular charges which accumulate on parts that are electrically insulated. Dust concentration Dust concentrations may be produced bv electrostatic phenomena, residual magnetism at the free end of the pipeline, for example at an insulating Joint.
1.4.2.3 1.4.2.3.1
1.4.2.3.2
1.4.2.3.3
1.4.2.3.4
Electrolytic phenomena This may occur with moist oxygen in the presence of metals or alloy of a different nature. Oxygen being maintained at low moisture content, these phenomena are not to be feared any more, they were mainly a cause of corrosion.
1.4.3
1.4.3.1
Factors Influencing Ignition

Lack of cleanliness Foreign bodies may cause ignition by : Friction or Impact Accumulation of static electricity and discharge
Joule Effect by accumulation of dust deposits. They may also transmit ignition because of their lower ignition temperature. 1.4.3.2 Abnormally high velocity The origin of an abnormal high velocity may be : Uncontrolled flow Venting too rapidly Fracture of a component or of the pipeline Too rapid pressurisation (this last case may also be accompanied by the effects of adiabatic compression) Leakage
These may displace foreign bodies and cause other phenomena such as thermodynamic heating, vibrations etc. 1.4.3.3 Incompatible or unsuitable materials The presence of these materials may be due to incorrect choice of materials that do not conform to specifications.
1982
Page 30 of 39
IGC
1.4.3.4
Temporary connections to other networks Accidents have occurred by inadvertently connecting oxygen pipelines to other gas lines. A more frequent occurrence is making temporary connections to other networks, for example connection to a nitrogen or air line for purging or pressurisation which can lead to the introduction of foreign matter in the oxygen line. Mechanical accidents on installations Such accidents may be due to : Bursting under gas pressure Fracture under mechanical stress Failure of equipment Blockage Over speeding of rotary meters Inadequate supporting of venting and main equipment Thermal stresses (Expansion/Contraction) Ground Stresses Various defects or bad workmanship Hydrostatic stresses (water table)
1.4.3.5
1.4.3.6
Poor workmanship & maintenance Bad assembly (internal assembly of a component or assembly of the whole) may be a source of tension, stress, vibration causing heating, dangerous deformation and even rupture. An undesirable object (a loose nut, washer, various elements) may originate from an element located upstream, which is badly designed or fitted. A leak at a joint may be the origin of an ignition or it can be a contributory or aggravating factor,. Unauthorised action This includes non-observance of general- and safety rules such as Operating instructions Prohibition of drilling, welding etc of a pipeline Prohibition of smoking
1.4.3.7
(See section 6 for details)
1.4.4
1.4.4.1
External Causes of Accidents

Mechanical damage Mechanical damage to the installations may be due to: The movement of vehicles or machines The movement of abnormal size transport and loads The blows of tools during digging operations The placing of sheet Diles or piles Loads upon the ground Explosives, shock wave
The movement or anchoring of ships They may cause : impact, penetration, tearing, crushing, wear.
1982
Page 31 of 39
IGC
1.4.4.2
Thermal Effects Thermal effects through heating or cooling may originate from : A hot spot (torch arc, etc) Hot products (metal, scale etc) Low temperatures (cold due to expansion of the gas) Very low temperatures (liquid oxygen, liquid nitrogen etc)
Thermal shocks may cause ignition by introducing energy from outside, or they may cause dangerous change to the mechanical characteristics of the metal. 1.4.4.3 Corrosion External corrosion due to failure of the protective coating may cause deterioration of the pipes to the point where penetration or bursting may occur. In the ground corrosion may be slow or rapid according to the corrosivity of the soil, and by the presence of stray currents. Corrosion by contact with other elements of different potential may result in penetration of the pipe. This may occur in the ground and above ground by contact with other elements. In the case of above-ground structures corrosion by atmospheric pollution should also be taken into consideration. 1.4.4.4 Proximity of high tension electric cables The accidents caused by the proximity of high tension electric cables can be classed in three categories, according to the nature of the electrical phenomenon. (a) Direct Contact This is an accidental contact or a discharge by short circuit to the earth in the case of default. The energy involved by this type of incident can result in penetration of the tube. Capacitive Connection This is the capacitive influence on insulated section or pipe during positioning work so that it is recommended these sections are connected to earth before assembly. Inductive Connection This is the influence of magnetic fields due to alternating current on electric cables running parallel to the pipeline. In all the above cases the pipeline may carry the electric current. The following practices shall be prohibited due to the accidents they may involve. Connection of pipeline to other installations Conductive connection between pylon and pipeline Pipeline used as an earth
(b)
(c)
Pipeline or installation in service used as an earth terminal during welding operations (see Figure 52, Tables 13 & 14 and paras. 4.3.5.22 & 4.3.5.24)
1982
Page 32 of 39
IGC
1.4.4.5
Natural Causes Movements of the earth : ground slip subsidence erosion earthquake
change in water table and the elements : wind rain variations of temperature
lightning These causes may bring about deformation and even rupture, lightning may also cause fusion of metal or the passage of dangerous currents.
1.4.5
Internal Explosions in Pipelines

The presence of gas or flammable vapour in the oxygen may be due to the following reasons : Installation inadequately rinsed after cleaning with products which are flammable in oxygen. Feed-back of a combustible gas or product into the oxygen pipeline from a utilisation point.
Incorrect connection. These mixture may produce explosions. An energy source is necessary to ignite the mixture, one of the energy sources mentioned in 1.4.2. An external source of heating Self ignition Ignition at a usage point resulting in flashback to the pipeline
As shown in 2.2.2.6 certain solvents in the presence of certain metals can produce explosive mixtures by chemical reaction.
1.4.6
Oxygen - Enriched Atmosphere

Any enrichment of the air with oxygen will increase the risk of ignition especially of the clothing of personnel. This risk is critical in trenches or enclosed spaces where repairs or modifications are carried out. oxygen enrichment prohibits welding opertions. Causes of oxygen enrichment may be : Leakage due to faulty equipment Perforation Porous metal Weld leakage Leakage at flanges and seals
Valves leaking into work area Leakage from vent pipework Venting Purging Feed-back of oxygen due to incomplete purging before work or isolation Wrong usage or badly adjusted equipment
Forbidden usage (Air refreshment, Ventilation, Pheumatic tools etc) If there is leakage the oxygen concentration increases, this concentration in an area can also be transferred to any area from the point of leakage.
1982
Page 33 of 39
IGC

Apart from the cigarette we list other causes of ignition : Cutting and welding tools Electric welding processes Metal and scale projections from operations of either cutting or welding Sparks from electrical equipment or over-heating Sparks from grinding Sparks produced by impact Oxidation of paint during drying
1.4.7
Explosive Atmospheres
An atmosphere may become explosive if fuel gases are present, whether air or oxygen enriched air is involved. Combustible gas or vapours may originate from : Vapour from products being stored or used e.g. degreasing agents Cases used with oxygen (Feed-back, Leakage)
Equipment used (Cutting and Welding torches) Ignition factors are the same as those mentioned in 1.4.6. Special attention shall be paid to this danger when work is being carried out in a trench. (Note : Fuel gases are usually heavier than air).
1.4.8
Oxygen Deficient Atmosphere

Nitrogen is frequently used for cleaning, blowing, purging, leak-tightness and pressure testing. Because of the physiological dangers of an atmosphere deficient in oxygen, precautions shall be taken to ensure that such a condition does not exist due to the use of nitrogen. Special attention shall be paid to this danger when work is being carried out in a trench. The danger increases when using cold nitrogen vaporised from liquid. Cold gases are heavier than air and tend to concentrate at low level and are difficult to dissipate (Note : Nitrogen is normally lighter than air, but at 0C is heavier than air at 15C).
1.4.9
Normal Electrical Dangers

Oxygen installations shall be protected against electrical dangers of the traditional type. Standard practices or regulations shall be observed.
1.4.10
Points Where Accidents May Occur

A pipeline for which these recommendations for construction and cleanliness have been observed cannot normally be the origin of an accident. on the other hand the fitted components constitute the weak points of installation where ignition generally originates. Because of this, components shall be restricted to the minimum necessary. The points where there are components shall be points where generally speaking protection shall be assured (see 4.2).
1.4.11
Circumstances of Accidents
Experience has shown that a large proportion of accidents occur after modification maintenance, putting into service or return to service after a short time. Generally, there is at the time of an accident, a high gas velocity, but not always, some accidents have occurred in installations under pressure but at rest.
1982
Page 34 of 39
IGC
1.4.12
Synoptic Table
Table III summaries the causes and effects of accidents in oxygen distribution networks
1982
Page 35 of 39
IGC
1.5
1.5.1
REGULATIONS
Official Regulations and Recommendations
As a general rule the regulations, whether national or local, refer to various gaseous products under pressure. A distinction is generally made between various gases under pressure, combustible, toxic, corrosive, combustive, etc. Few countries have regulations which take into account all characteristics of gaseous oxygen. West Germany has official regulations, according to which materials are tested for their suitability, supplemented by authorisation for the use of non-metallic materials with oxygen. On the European level there are also the recommendations of the European Economic Communities (EEC). These recommendations concern oxygen installations for iron and steelmaking. They were drafted by the General Commission on Safety and Hygiene in the Iron and Steel Industry. Professional organisations have in most countries issued recommendations for the use of members, namely : The committee of oxygen producers: The IGC in Europe (Industrial Cases Committee) The CCA in U.S.A. (Compressed Gases Association)
The technical association of the iron and steel industry
The chemical industries group A number of companies have their own rules for design, installation and operation : Companies producing and distributing oxygen Iron and steel producing companies Chemical companies Petrochemical companies
1.5.2
Scope of Official Regulations

Usually the relevant regulations originate directly from those for pressure vessels or refer to them. Essentially problems of mechanical strength are dealt with and the regulations, therefore, concern : The characteristics of materials The allowable stress of materials The methods of testing or of approval The methods of calculation The pressure safety devices
Inspections and repeat tests A distinction may be made between factory pipelines and transportation pipelines. Pipelines for the transportation of gases under pressure may also be subject to : Safety regulations related to pipeline route (extra thickness standards for burying and spacing of pipes) Legal regulations concerning the land, which define the conditions of granting a right of way by third parties for the laying, operation or maintenance of the pipes
Commercial regulations associated with the license to operate relating to the pipeline Valve stations or distribution stations may be subject to regulations with regard to construction. These regulations may affect the method of construction or lay down certain requirements concerning location, aesthetics or protection.
1982
Page 36 of 39
IGC
1.5.3
Environmental Problems
In addition to regulations concerning construction there are two other factors that may affect the environment, namely noise and cold due to expansion in the vicinity of distribution stations. Specific regulations concerning noise show an increasing tendency in most countries.
1.5.4
Dominance of Local Law

All official, compulsory or public order regulations will prevail in the country or zone of application. The legal provisions shall always remain preponderant over the provisions of this code.
1.6
1.6.0
Guidance for the Prevention of, Protection Against, and Means of Combating Accidents
General
In earlier sections we have observed the characterisics of risks associated with oxygen distribution installations. In this connection we have already defined a number of preventive parameters with regard to concentration and velocity. In the sections that follow we shall develop the rules it is appropriate to observe in order to design, construct and operate the installations with a minimum of risk. These measures relating to the prevention of, protection against, and the means of combating accidents will be dealt with from the various points of view enumerated below :
1.6.1
Prevention
Prevention concerns the measures which should be taken in connection with installations and actions with a view to eliminating the causes of accidents.
1.6.1.1
For the whole Competent personnel forewarned of the problems Limitation of the gas velocity Cleanliness of installations and installed equipment Electrical continuity of installations and equipment (see 4.2.5.14) Knowledge of the environment Control and supervision of work Selection of materials General Design Design of equipment Method construction and control Selection of products Procedures for use Design of installations Selection of operating procedures Automatic controls Control and detection instruments Safety equipment Assembly procedures
1.6.1.2
For the equipment
1.6.1.3
For materials
1.6.1.4
For the installations
1982
Page 37 of 39
IGC
1.6.1.5 1.6.1.6
For work on the installations Programme of inspection and maintenance working procedures detection of oxygen content ventilation training of personnel pipeline identification keeping documents up to date supervision of installations
Protection gainst third parties
1.6.2
Protection of Persons
Measures to be taken to minimise the consequences of an accident. Design Electrical protection Protective screens and enclosures Access and escape Escape facilities
1.6.3
Combating Accidents
The actions taken in order to arrest or limit the extent of an accident or its consequences. Emergency planning Emergency action Safety training Remote operations Extinguisher Sprinkler Pipeline purging and venting Plans of action Persons who act
Means
Emergency Notices
Training of action teams
1982
Page 38 of 39
IGC
1.7
1.7.1
Inspection of Equipment and Installations

The Need for Inspection
In order to avoid accidents, oxygen distribution installations shall be correctly constructed and comply with normal technical rules and the recommendations of this code. Inspection is required to ensure that the rules are observed.
1.7.2
1.7.2.1
Inspection
Scope Inspection shall be applied to cleanliness required materials design of the pipeline and installation construction (manufacture, welding, laying, etc) testing operation and maintenance
1.7.2.2
Application Inspection is carried out during design on the components or elements manufactured at the suppliers works on components supplied from stockists at the work site before putting into service at the time of putting into service during operation during maintenance
1.7.3
Training of Personnel
At a large work site it is necessary to introduce specialist personnel to ensure control. In many cases, inspection will be carried out by construction personnel or by operating personnel. Personnel shall have been made aware of the dangers inherent in oxygen. They will have received adequate training. Personnel installing, operating or maintaining the pipelines shall also be informed and trained with regard to possible electrical influences and to the rules to be observed. For large pipeline networks, service teams trained with maintenance or operational personnel capable of being mobilised in case of emergency shall be made available
1982
Page 39 of 39
IGC
IGC 13/82 The Transportation and Distribution of Oxygen by Pipeline Part 2 : Materials and Products - Cleaning
The Transportation and Distribution of Oxygen by Pipeline Part 2 : Materials and Products - Cleaning
IGC 13/82/E
1982
Page 1 of 30
IGC
SECTION 2: MATERIALS AND PRODUCTS - CLEANING...................................................................................4 2.1 M ATERIALS AND PRODUCTS...................................................................................................................................4 2.1.0 General..................................................................................................................................................................4
2.1.0.1 2.1.0.1 Material selection ............................................................................................................................................ 4 Recommended materials................................................................................................................................... 4 Behaviour in oxygen ........................................................................................................................................ 4 The metals in general use.................................................................................................................................. 4 Cast iron .......................................................................................................................................................... 5 Aluminium and its alloys.................................................................................................................................. 5 Metal deposits.................................................................................................................................................. 5 Behaviour in oxygen ........................................................................................................................................ 8 Permissible uses ............................................................................................................................................... 8 Mass limitations............................................................................................................................................... 8 Material selection ............................................................................................................................................ 8 Identification ................................................................................................................................................... 8 Reinforcements and additives ........................................................................................................................... 8 Material characteristics..................................................................................................................................... 8 Recommended resins and elastomers................................................................................................................ 9 Examples ......................................................................................................................................................... 9 Proof of compatibility ...................................................................................................................................... 9 Ceramics........................................................................................................................................................ 10
2.1.1
Metals ....................................................................................................................................................................4
2.1.1.1 2.1.1.2 2.1.1.3 2.1.1.4 2.1.1.5
2.1.2
Plastic or Organic Materials.............................................................................................................................8
2.1.2.1 2.1.2.2 2.1.2.3 2.1.2.4 2.1.2.5 2.1.2.6 2.1.2.7 2.1.2.8
2.1.3
Other Materials....................................................................................................................................................9
2.1.3.1 2.1.3.2 2.1.3.3
2.1.4
Gaskets, Seals, Packings, Sealing Compounds........................................................................................... 10
2.1.4.1 Material selection .......................................................................................................................................... 10 2.1.4.2 Seals for Flanges and Component Elements.................................................................................................... 10 2.1.4.3 Valve seat inserts ........................................................................................................................................... 10 2.1.4.4 Gland seals..................................................................................................................................................... 11 2.1.4.5 Thread seals ................................................................................................................................................... 11 2.1.4.6 Sealing compounds......................................................................................................................................... 11 2.2 M ISCELLANEOUS PRODUCTS.................................................................................................................................11
2.2.1
Lubricants.......................................................................................................................................................... 11
Limitations of use........................................................................................................................................... 11 Classification ................................................................................................................................................. 11 Lubrication products ...................................................................................................................................... 11 Recommended lubricants................................................................................................................................ 11 General .......................................................................................................................................................... 13 Halogenated solvents ..................................................................................................................................... 13 Solvent Characteristics ................................................................................................................................... 13 Formation of explosive mixtures..................................................................................................................... 15 Temperature and ultra violet effects on solvents.............................................................................................. 15 Reaction with Metals...................................................................................................................................... 15 Other cleaning agents..................................................................................................................................... 15 Prohibited degreasing agents .......................................................................................................................... 15 General .......................................................................................................................................................... 16 Chemical cleaning and descaling agents.......................................................................................................... 16 Chemical protective agents............................................................................................................................. 16 Other products ............................................................................................................................................... 16 Abrasives ....................................................................................................................................................... 16 Propellant gas................................................................................................................................................. 17 Brushes.......................................................................................................................................................... 17 Cleaning pigs ................................................................................................................................................. 17 Cleaning cloths .............................................................................................................................................. 17 Nitrogen ........................................................................................................................................................ 17 Air ................................................................................................................................................................. 17 Products......................................................................................................................................................... 17 Application.................................................................................................................................................... 17 Quantities ...................................................................................................................................................... 17
2.2.1.1 2.2.1.2 2.2.1.3 2.2.1.4
2.2.2
Degreasing Agents and Solvents.................................................................................................................... 13
2.2.2.1 2.2.2.2 2.2.2.3 2.2.2.4 2.2.2.5 2.2.2.6 2.2.2.7 2.2.2.8
2.2.3
Cleaning Agents and Protective Products.................................................................................................... 16
2.2.3.1 2.2.3.2 2.2.3.3 2.2.3.4
2.2.4
Mechanical Cleaning Products and Equipment.......................................................................................... 16
2.2.4.1 2.2.4.2 2.2.4.3 2.2.4.4 2.2.4.5
2.2.5 2.2.6
Purging and Testing Gases............................................................................................................................. 17 Dessicating Products ....................................................................................................................................... 17
2.2.5.1 2.2.5.2 2.2.6.1 2.2.6.2 2.2.6.3
1982
Page 2 of 30
IGC
2.2.7 2.2.8
2.2.7.1 2.2.7.2
Leak Detectors .................................................................................................................................................. 18

Products for external use ................................................................................................................................ 18 Products for internal use ................................................................................................................................. 18
Other Products.................................................................................................................................................. 18
2.2.8.1 Water ............................................................................................................................................................ 18 2.2.8.2 Anti-freeze..................................................................................................................................................... 18 2.2.8.3 Paints............................................................................................................................................................. 18 2.2.8.4 Products for temporary sealing ....................................................................................................................... 18 2.2.8.5 Sound insulation products............................................................................................................................... 18 2.2.8.6 Other Products ............................................................................................................................................... 18 2.3 CLEANING ................................................................................................................................................................19
2.3.0
General Considerations................................................................................................................................... 19
Cleanliness..................................................................................................................................................... 19 Contaminants................................................................................................................................................. 19 Object and nature of cleaning ......................................................................................................................... 20
2.3.0.1 2.3.0.2 2.3.0.3
2.3.1 2.3.2
Preliminary Cleaning ...................................................................................................................................... 20 Degreasing With Solvents ............................................................................................................................... 20

Products......................................................................................................................................................... 20 Degreasing by immersion ............................................................................................................................... 20 Degreasing by circulation ............................................................................................................................... 22 Degreasing by vaporisation ............................................................................................................................ 22 Cleanliness of solvents................................................................................................................................... 22 Elimination of solvent residues ....................................................................................................................... 22 Methods......................................................................................................................................................... 23 Applications .................................................................................................................................................. 23 Aims and effects of this treatment .................................................................................................................. 23 Products......................................................................................................................................................... 23 Methods......................................................................................................................................................... 23 Chemical pickling .......................................................................................................................................... 23 Phosphating and passivation........................................................................................................................... 23 Duration of treatments.................................................................................................................................... 25 Processes and applications ............................................................................................................................. 25 Products and equipment ................................................................................................................................. 25 Manual methods............................................................................................................................................. 25 Sand and shot-blasting.................................................................................................................................... 25 Passage of cleaning pigs ................................................................................................................................. 25 Blowing out the pipelines ............................................................................................................................... 26 Vacuum cleaning............................................................................................................................................ 26 Cleaning of components................................................................................................................................. 26 Cleaning prefabricated pipework .................................................................................................................... 27 Cleaning the pipes.......................................................................................................................................... 27 Methods......................................................................................................................................................... 27 Pipelines constructed with unclean pipes ........................................................................................................ 28 Pipelines constructed-with clean pipes............................................................................................................ 28 General .......................................................................................................................................................... 28 Control of cleanliness..................................................................................................................................... 28 Direct control of degreasing............................................................................................................................ 29 Indirect control of degreasing.......................................................................................................................... 29 Methods of inspection .................................................................................................................................... 29 General .......................................................................................................................................................... 29 Packaging of small items................................................................................................................................ 29 Sealing of components and sections of pipework ............................................................................................ 30 Sealing pipes.................................................................................................................................................. 30 Drying agents................................................................................................................................................. 30 Inerting.......................................................................................................................................................... 30 Labelling........................................................................................................................................................ 30
2.3.2.1 2.3.2.2 2.3.2.3 2.3.2.4 2.3.2.5 2.3.2.6
2.3.3 2.3.4
Degreasing with Water Solutions or Steam................................................................................................. 23 Treatment with Acid Products........................................................................................................................ 23
2.3.3.1 2.3.3.2 2.3.4.1 2.3.4.2 2.3.4.3 2.3.4.4 2.3.4.5 2.3.4.6
2.3.5
Mechanical Cleaning ....................................................................................................................................... 25
2.3.5.1 2.3.5.2 2.3.5.3 2.3.5.4 2.3.5.5 2.3.5.6 2.3.5.7
2.3.6
Cleaning of Components and Equipment..................................................................................................... 26
2.3.6.1 2.3.6.2 2.3.6.3
2.3.7
Cleaning the Pipelines..................................................................................................................................... 27
2.3.7.1 2.3.7.2 2.3.7.3
2.3.8
Level of Cleanliness and Control................................................................................................................... 28
2.3.8.1 2.3.8.2 2.3.8.3 2.3.8.4 2.3.8.5
2.3.9
Preservation of the Cleanliness Obtained.................................................................................................... 29
2.3.9.1 2.3.9.2 2.3.9.3 2.3.9.4 2.3.9.5 2.3.9.6 2.3.9.7
1982
Page 3 of 30
IGC
SECTION 2: MATERIALS AND PRODUCTS - CLEANING

2.1
2.1.0
2.1.0.1
Materials and Products

General
Material selection In this part we consider the choice of materials. Metals are generally speaking materials of well defined composition, worked at high temperature. This is often not the case with numerous other materials such as plastics, lubricants and various other products. This is because of the difference in procedure for manufacture, in the use of fillers and in the multitude of products manufactured each for a very specific industrial need. It is necessary to state that the materials indicated below are in many cases a guide which will assist in making a choice but that it is necessary to make sure that chemical and physical qualities are maintained. A single commercial name may designate a whole family of Products which are not necessarily all usable with oxygen. It is, therefore, necessary to specify the quality and type corresponding to the composition and manufacture which have been judged to be valid for the specific use to which the product is to be put. Recommended materials Metals are recommended for the construction of components and pipelines. Non-metallic materials may be used only for the applications indicated in 2.1.2 and subject to careful selection.
2.1.0.1
2.1.1
2.1.1.1
Metals
Behaviour in oxygen Metallic materials generally have a high ignition temperature in oxygen (see Table iv). Copper and its alloys, nickel and its alloys (monel, inconel) ignite only with difficulty. Carbon steel and stainless steel enable combustion to continue very easily by reason of the heat released provided that the supply of oxygen remains sufficient to support the combustion. The thermal conductivity of stainless steel is less that that of carbon steel. The ignition temperature of stainless steel is higher than that of carbon steel but it burns more rapidly and with greater intensity than the latter. Aluminium and its alloys burn in the gas phase after melting and evaporation of the metal. The metals in general use The metals in general use for the construction of components and elements of pipelines are: nickel and its alloys (monel, inconel... ) copper and its alloys (bronzes, brasses... ) unalloyed or low alloy steels and cast steels stainless steels. In the case of certain components, part or all of the constituent metals is the subject of recommendations or restrictions stated in 3.6 in conjunction with the following considerations: design of the installation conditions of operation (velocity, pressure, temperature) function of the component design of the component presence of plastic or organic materials safety devices
2.1.1.2
1982
Page 4 of 30
IGC
2.1.1.3
Cast iron Lamellar or spheroidal graphite cast irons whether alloyed or not may be used for the fabrication of components on condition that these components do not have to withstand forces due to gas pressure. For making pressurised enclosures certain cast irons may be employed under certain conditions fixed by the legislation in force in the country. Aluminium and its alloys For pipelines covered by this code the use of aluminium and its alloys should be avoided as far as possible unless experience and testing has demonstrated its safe use. Metal deposits Metal deposits made electrolytically or by welding or brazing are permitted on condition that: the application processes do not introduce other elements incompatible with oxygen. the materials (both base and deposit) are chosen as a function of their respective characteristics so as to ensure perfect adhesion of one to the other. Typical uses: preventing corrosion reducing friction increasing locally surface hardness improvement of heat dispersion
2.1.1.4
2.1.1.5
1982
Page 5 of 30
IGC
1982
Page 6 of 30
IGC
1982
Page 7 of 30
IGC
2.1.2
2.1.2.1
Plastic or Organic Materials

Behaviour in oxygen Plastic or organic materials have a distinctly lower ignition temperature than metallic materials (see Table v). If ignited they may eventually heat particles and adjacent metal components to the point of ignition. It is, therefore, good practice to use such materials in the smallest possible quantities and only in intimate contact with metallic parts of greater mass and good conductivity to dissipate the heat. Copper and most of its alloys possess this quality. For a given ignition temperature, plastic and organic materials with less heat of combustion and a lower combustion rate, are preferred to reduce the possibility of transitting heat to the metal. Permissible uses The use of plastic or organic materials in direct contact with oxygen shall be limited to the following: (See 3.6) seals and packings in components and assemblies deformable elements (diaphragms) in servomotors and regulating devices. antifriction elements (pedestal and thrust bearings) antifriction coatings electrical insulation for cathodic protection hoses Mass limitations In every case their mass shall be as small as possible and they shall be employed only when a metallic element is unsuitable. Material selection In countries where official regulations exist specifying the materials that may be used with oxygen and qualify their use (pressure, temperature functions), it is possible to choose among the products recommended, while nevertheless giving preference to fluorinated or chlorofluorinated resins and elastomers. Identification It is recommended that fluorinated elastomers (diaphragms, O-ring seals, etc) have a distinctive mark to prevent any confusion with the elastomers. Reinforcements and additives Fluorinated and chlorofluorinated resins can be reinforced with oxides, asbestos, glass ceramic, metals and alloys in order to improve some of their mechanical properties. Such reinforcement shall not affect resistance to ignition. Similarly, certain methods of manufacture which involve the use of additives such as the binders shall not lower ignition temperature below that of the base product. It is therefore necessary to check for each batch that the products have the same ignition temperature as the base product. Material characteristics In the choice of plastic or organic material, selection according to the property of resistance to ignition is of paramount importance. These materials shall, however, comply with other properties connected with their use: friction properties mechanical strength resistance to wear flexibility sealing properties insulation properties Certain characteristics may render plastic or organic materials unsuitable for a particular use, such as a tendency to flow.
2.1.2.2
2.1.2.3
2.1.2.4
2.1.2.5
2.1.2.6
2.1.2.7
1982
Page 8 of 30
IGC
The PTFEs (eg Teflon) while possessing excellent antifriction properties are products which flow easily. By contrast the PTFCEs (eg Voltalef, Kel-F) have slightly less antifriction properties but much better resistance to flow. The fluorinated resins (PTFE) and the chlorofluorinated resins (PTFCE) also have a tendency to sublimiate under certain conditions of pressure and teMDerature. The various characteristics of these products can be modified or improved by means of fillers incorporated in the course of their manufacture (see 2.1.2.6). Table VI summaries a number of initial recommendations for selection which will be elaborated in the sections that deal with the design of components. TABLE VI PROPERTIES Good antifriction Tendency to flow Tendency to sublimiate (Can be reinforced to improve strength)
PRODUCT PTFE and FEP
USES Valve seats Antifriction bearings Antifriction coatings Thrust washers Thread seals Gland Packings Valve seats Bearings Insulating seals Gland packings O-rings seals Diaphragms
PTFCE
Harder than PTFE Greater mechanical strength than PTFE and FEP
Fluorinated chlorofluorinated elastomers (Viton)
Flexibility Elasticity
2.1.2.8
Recommended resins and elastomers Among the fluorinated and chlorofluorinated resins and elastomers those listed below are acceptable: Fluorinated resins Polytetrafluorethylene (P.T.F.E) Teflon, Hostaflon, Soreflon, Fluon, Algoflou)* Polyfluorethylene propylene (F.E.P) (Teflon FEP)* Polyfluoride of vinylidene (P.V.F.2) (Kynar)* Chlorofluorinated resins Polymonochlorotrifluoroethylene (P.T.F.C.E) (Kel-F 300, Voltalef 300)* Monochlorotrifluoroethylene-Fluorovinylidene copolymer (P.T.F.C.E) (Kel-F 500, Voltalef 500, Diaflon)* Fluorinated elastomer Flurovinylidene-hexafluoropropylene copolymer (Viton, Fluorel, Refset)* Chlorofluorinated elastomer Fluorovinylidene-monochlorotrifluoroethylene copolymer (Kel-F 5 500)* * Trade names of products in use at the time of publication.
2.1.3
2.1.3.1
Other Materials
Examples Filter elements can be made from sintered bronze, bronze alloy mesh, glass fibre or ceramic subject to the recommendations of section 3.6.5. Proof of compatibility The ignition temperature in oxygen of some of these materials, especially of asbestos compounds, varies with the method of manufacture and any additives (fillers or binders) used. They shall only be used if previous tests have proved their safe use.
2.1.3.2
1982
Page 9 of 30
IGC
2.1.3.3
Ceramics Ceramics offer excellent resistance to ignition but their low mechanical strength generally limits their use.
2.1.4
2.1.4.1
Gaskets, Seals, Packings, Sealing Compounds

Material selection The materials that may be used for the manufacture of gaskets, seals and packings in flange connections, plugging devices, stuffing boxes, screw couplings, etc., shall be selected from among those mentioned in previous sections. the metallic materials in 2.1.1.2 the resins and elastomers in 2.1.2.8 the miscellaneous materials in 2.1.3 The choice will depend upon the form and use of the product. Seals for Flanges and Component Elements Various types of seals which may be used are shown in 3.4 Types of seals and materials of construction are show in Table VII. TABLE VII TYPE OF SEAL Metallic Flat seals SEAL MATERIAL Annealed red copper Aluminium Silver-gold O-ring seals (blind or hollow) Seals of special shape and S seals Silver copper Stainless steel Nickel, Monel, Iconel Nickel, Monel, Iconel Stainless steel Carbon steel Copper Composite Spiral wound gaskets (Flat seals) Spiral part: Stainless steel Nickel, Monel Iconel Interpolation: Graphite, Ceramic PTFE, asbestos
2.1.4.2
Non-metallic
Formed seals O-ring seals Moulded seals on a metallic support (Flat seals in sheet form)
Fluorinated resins Chlorofluorinated resins Fluorinated elastomers Chlorofluorinated elastomers Fluorinated elastomers Chlorofluorinated elastomers Asbestos fibres with various binders
NOTE:For non-metallic materials, refer to 2.1.2 and 2.1.3 for precautions to be taken. 2.1.4.3 Valve seat inserts The seals for valve seat inserts shall be made with Fluorinated and chlorofluorinated resins and elastomers. (See 2.1.2.8)
1982
Page 10 of 30
IGC
2.1.4.4
Gland seals Gland seals may be made by using fluorinated and chlorofluorinated resins and elastomers. They may also be made up of asbestos braid impregnated with PTFE. Certain type of graphite based seals may be used. Gland seals of uncompacted PTFE fibre or of PTFE powder are not recommended. Thread seals Only PTFE tape may be used. The tape shall not protrude into the gas stream. Vegetable fibres such as hemp, etc., are prohibited for use with oxygen. Sealing compounds All products such as dressings, glues, sealing pastes, whether liquid or powder or paste, intented to ensure leak-tightness or adhesion between elements shall not be used unless tests have proven them to be safe with oxygen.
2.1.4.5
2.1.4.6
2.2
2.2.1
2.2.1.1
Miscellaneous Products
Lubricants
Limitations of use Generally, the use of lubricants should be avoided, preference being given to devices that operate without lubrication,, The use of lubricant shall be strictly reduced to the minimum. It should preferably be incorporated for life when the component is assembled and not be visible externally. Classification The lubricants for use with oxygen may be classified into two categories: a) Lubricants in direct contact with oxygen under pressure. Certain national regulations specify for each product a maximum pressure and temperature. b) Lubricants applied to components designed for use with oxygen but not in direct contact with the gas, e.g. on gear boxes or other devices for the operation of valves. Steps shall be taken to avoid oxygen pressure build up in the enclosures containing these lubricants. Lubrication products At present five basic products may be used for lubrication in the presence of gaseous oxygen: graphite molybdenum disulphide fluorinated or non-fluorinated silicones polymers of monochlorotrifluoroethylene perfluorinated polyethers a) Graphite and molybdenum disulphide are generally supplied in the form of very fine dry powders or packed in aerosols. b) Silicones, polymers of monochlorotrifluoroethylene and perfluorinated polyethers are offered in liquid form (oil) or in the form of pastes (greases). c) The greases differ from the oils in that they contain a jelling product. This product shall be non-combustible (e.g. Silica gel). Recommended lubricants Table VIII divides the lubricants into those that may be used with oxygen under pressure and those that may only be used in contact with oxygen at low pressure subject to national regulations.
2.2.1.2
2.2.1.3
2.2.1.4
1982
Page 11 of 30
IGC
1982
Page 12 of 30
IGC
2.2.2
2.2.2.1
Degreasing Agents and Solvents

General Oils and greases are dangerous products in the presence of oxygen and their elimination shall, therefore, be correctly ensured before any equipment is put into service. This section deals with degreasing products, most of which in the presence of air or oxygen are capble of igniting or of creating explosive atmospheres. Every degreasing operation shall be followed by the removal of the residual solvents. National regulations shall be followed concerning the use of these products which are generally toxic, inflammable, whose vapours are heavier than air (protective clothing, ventilation, etc). Methods of degreasing and control are described in chapter 2.3. Halogenated solvents Halogenated solvents such as the following solvents are suitable for use as degreasing agents. Trichloroethylene Dichloroethylene Perchloroethylene Trichloroethane Pentachloroethane Carbon tetrachloride Methylene chloride Monofluorotrichloroemthane Difluorotetrachloroethane Trifluorotrichloroethane, etc Solvent Characteristics Table IX indicates the main characteristics of the most commonly used solvents. Table IX also shows the classification of solvents as a function of their toxicity, solvent power and flammability in oxygen. Solvents are generally toxic and may act on the human body through inhalation, penetration of the skin and ingestion. Dichloroethylene, Pentechloroethane, Carbon tetrachloride, Trichloroethylene, Difluorotetrachloroethane are not recommended due to their high toxicity, unless special precautions are taken.
2.2.2.2
2.2.2.3
1982
Page 13 of 30
IGC
1982
Page 14 of 30
IGC
(1)
The KAURI-BUTANOL index of a solvent corresponds to the volume of solvent which when added to a solution of kauri gum in butanol causes commencement of cloudiness in the solution. The better the product is as a solvent, the higher the value of this figure. (2) TLV. The TLV value (threshold limit value) is the maximum concentration of a substance in the form of gas, vapour or body in suspension in the air at the place of work which according to present knowledge generally does not injure the health of an employee or disagreeably inconvenience even after repeated or continuous exposure as a general rule for 8 hours a day or 45 a week. The figures shown are those published by the Ministry of labour and Social Affairs of the German Federal Republic. (3) The evaporation rate is the ratio between the evaporation time of the liquid concerned and that for diethyleter at a temperature of 20 + 2C and a relative humidity of 65% + 5%. (4) The minimum ignition temperature is the minimum temperature of ignition of the most flammable mixture with air or oxygen. (5) The pressure developed in a closed vessel by the most explosive mixture ignited at 1013 mb. SOLVENTS ARE USUALLY SUPPLIED IN UNSTABLISHED FORM NOTE:The values given in this table are extracted from specialised publications. The choice of solvent for a given application shall be the best compromise basedon the various properties listed in the table IX and the following paragraphs. 2.2.2.4 Formation of explosive mixtures Most chlorinated solvents are capable, at moderate temperatures, of forming vapours which, under certain concentrations with air or oxygen produce mixtures that are readily explosive. In addition, some mixtures of these chlorinated solvents with oxygen under pressure may ignite if their temperature exceeds 200C. In addition to avoiding localised heat concentrations. It is recommended NOT to: use heated chlorinated solvents blow with hot air in order to dry elements degreased by means of a chlorinated solvent. use chlorinated solvents for cleaning closed tanks or other elements where it is not possible to ensure total removal of the solvent. 2.2.2.5 Temperature and ultra violet effects on solvents Chlorinated or fluorinated solvents may decompose in the presence of sources of heat ( > 200C) ultra violet rays and of atmospheric humidity to form very toxic gases, e.g. phosgene. Smoking and the performance of any operations involving the use of flame arcing or other source of heat greater than 200C shall, therefore, be prohibited on premises where vapour of halogenated solvents are present. Reaction with Metals Some chlorinated or fluorinated solvents are capable of forming explosive products with alkali metal or alkaline earth metals, especially if the latter are in a finely divided state (chips, filings, etc). Chlorinated solvents other than perchloroetylene for degreasing light alloys shall be stablised and proven suitable for the purposes. Other cleaning agents It is also possible to use certain detergents or chemicals dissolved in hot or cold water provided that the compatibility of any residues with oxygen has been examined previously. The degreasing power of these products is lower than that of halogenated solvents. Their use also requires precautions detailed in 2.3 in particular the need for careful drying of the parts. 2.2.2.8 Prohibited degreasing agents Derivatives of petroleum products (petrol, kerosine, acetone, etc) aliphatic and aromatic solvents, other than those listed in 2.2.2.2 and their derivatives like alcohols, esters and ketones which are sold under different names shall not be used because they are highly flammable and also may have low threshold limit values (TLV).
2.2.2.6
2.2.2.7
1982
IGC
2.2.3
Cleaning Agents and Protective Products

This section deals with descaling and chemically protective products. Products designed for mechanical cleaning are dealt with in 2.2.4. Methods of operation and control are dealt with in 2.3. it is compulsory to observe national regulations concerning the use and handling of these products which are generally toxic and corrosive.
2.2.3.1
General Scale, bituminous internal costings and certain varnishes generally cannot be removed from internal surfaces by means of the solvents indicated in 2.2.2 but require other chemical or mechanical cleaning. Descaling lays the metal bare and thus renders it vulnerable to attack by corrosion. It is, generally, followed by the application of protective products that inhibit corrosion. Chemical cleaning and descaling agents Aqueous solutions of acids such as : sulphuric aicd, H2 SO4 hydrochloric acid, HCl Nitric acid, HNO3 Phosphoric acid H3 PO4 may be used as chemical descaling agents. The degrees of concentration and the temperatures for using these solutions are indicated in 2.3 Products with a hydrochloric acid base shall only be used for carbon and low alloy steels. Products with a nitric acid base are intended only for non-ferrous metals such as aluminium, copper and their alloys; they mainly serve to deoxidise and polish the metal. Acid solutions which attack the base metal require the addition of inhibitors. For example nitric acid and hydrochloric acid. Chemical protective agents Aqueous solutions of : phosphoric acid, H3 PO4 chromium, copper or manganese salts soda, etc may be used as protective agents. Other products These are ready prepared products and solutions on the market designed either for descaling or for anticorrosive protection, or to fulfil both these functions simultaneously. Manufacturers generally do not give the exact composition of their products. They may, therefore, not be used unless previous tests have proven safety of the products or their dry residues for oxygen installations.
2.2.3.2
2.2.3.3
2.2.3.4
2.2.4
Mechanical Cleaning Products and Equipment

Mechanical cleaning includes operations such as sand blasting brushing, grinding scraping (pigging), etc Methods of application and control are dealt with in 2.3.
2.2.4.1
Abrasives Abrasives used for sandblasting operations should be inert in oxygen (free from oil or grease). Metallic shot (powders or grains of cast iron, iron, steel, etc) are capable of burning and initiating ignition. They shall, therefore be prohibited unless satisfactory removal can be assured. Preferably use will be made of silica sands (if national regulations permit) or other products which are not combustible in oxygen such as carburundum.
1982
Page 16 of 30
IGC
2.2.4.2
Propellant gas The propellant gas for sanding and shot blasting operations shall be clean dry oil free air or nitrogen. Propellant shall be considered oil free if its content of oil and grease is less than 0.005 g/Nm3 . It shall be considered dry if its relative humidity is less than 30% at working pressure. Brushes Brushes used for cleaning shall be of metal, with steel or bronze bristles. They shall be in good conditions and perfectly degreased before use. Handles of small hand brushes may be of wood. Cleaning pigs Scrapers for pipelines (pigs) shall be of metal. If they comprise brushes these shall comply with 2.2.4.3. If they comp 1rise non-metallic sealing (cups) rubbing against the walls of the pipes, these cups shall be made of fluorinated or chlorofluorinated resins or elastomers as indicated in 2.1.2. Cleaning cloths Cloths used for wiping components or small elements of pipelines shall be clean, free from traces of oil or grease and lint free.
2.2.4.3
2.2.4.4
2.2.4.5
2.2.5
2.2.5.1
Purging and Testing Gases

Nitrogen The purging or testing gas will preferably be dry oil free nitrogen, taken: from mobile transportation gas containers (cylinders, bundles, etc). from direct evaporation of liquid nitrogen from a nitrogen pipeline whose cleanliness has been verified Air Clean dry compressed air free from oil and grease may be used for purging or testing. Air shall be considered oil free if its content of oil and grease is less than 0.005 g/Nm3 and shall be considered dry if its relative humidity is less than 30% at working pressure. NB: Oxygen shall not be used for cleaning of installations under any circumstances.
2.2.5.2
2.2.6
Dessicating Products
Once cleaned, the components or elements of a pipeline may be provided with dessicating agents so as to prevent, during the period of storage, any corrosion or other deterioration due to the humidity of the air enclosed at the time of plugging or packing.
2.2.6.1
Products The following may be used as dessicating agents: silica gels regenerated clays crystalline silico-aluminates of sodium and calcium Certain colour additives may be included in the products to give an indication of the moisture content Application These products shall be packed in fabric or plastic sachets which shall be firmly fixed to the sealing plugs or plates of the component or element of the pipeline. In this way the possibility of them being forgotten and left inside the installations will be prevented. Small, loose capsules which may be left inside the component when it is fitted to the installation shall not be used. Quantities In order to be effective, the amount of dessicating agent shall be determined bearing in mind: the permeability and surface area of its packaging the storage time the volume of air enclosed the maximum percentage relative humidity permitted
2.2.6.2
2.2.6.3
1982
Page 17 of 30
IGC
2.2.7
2.2.7.1
Leak Detectors
Products for external use The detection of possible leaks from a component or coupling device may be effected with the aid of a 2% aqueous solution of Teepol. Some leak detector products packed in aerosols and used in the gas industry may also be used if previous tests have demonstrated their safe use with oxygen under their actual conditions of use. In most cases the dry residues of these products are flammable. The introduction of any combustible leak detector products into the interior of a component or circuit shall be avoided. The circuit shall be under pressure before application of the product. After testing, all traces of the product shall be removed with a clean, dry, lint-free cloth or by rinsing with potable water. If the search for leaks is effected by filling the circuit with clean, dry air or nitrogen the same products shall be used as for oxygen. The use of a flame or burning object to detect a leak is prohibited.
2.2.7.2
Products for internal use Leaks may be traced by the injection of Halogen or other products (Helium, N2 O) into the test gas and the use of suitable detectors. The use of odourising products is not recommended. Products currently on the market are toxic and flammable. Special precautions shall be taken according to the properties of the products injected.
2.2.8
2.2.8.1
Other Products
Water In the case of hydraulic testing of the pipeline potable water only shall be used providing this test is made after cleaning and degreasing operations. Pure water (potable or distilled) may be used as a hydraulic medium for control systems.
2.2.8.2
Anti-freeze Monoethylene glycol may be used as an anti-freeze addition in water. However, its content shall not exceed 20% by volume. Care shall be taken to ensure that water does not evaporate and leave residues of monoethylene glycol which is combustible in oxygen. If the system includes filtration, care shall be taken that filter elements have a sufficient permeability to prevent separation of the anti-freeze additives. For example, solution of water glycol may be separated by sieves of a permeability of 20 microns. Paints All paints and varnishes are prohibited inside components or pipeline elements subject to an oxygen atmosphere. Products for temporary sealing Spheres or inflatable cylinders used as temporary sealing plugs should preferably be of fluorinated or chlorofluorinated elastomer but may also be of polyurethane or copolymer of isobutylene and isoprene. Sound insulation products Mineral wool (glass wool or rock wool) may be used for insulation in the manufacture of silencers for vents, or for the manufacture of sound insulation casings on component parts or on piping. The product shall be of low oil content. Residual oil shall not exceed 0.2% by weight and shall be evenly distributed. Other Products No products other than those recommended in 2.2 may be used with oxygen unless prior tests have proved their safe use.
2.2.8.3
2.2.8.4
2.2.8.5
2.2.8.6
1982
Page 18 of 30
IGC
2.3
2.3.0
2.3.0.1
Cleaning
General Considerations
Cleanliness Cleanliness is a fundamental safety requisite for oxygen installations. It is not sufficient for the cleanliness to be effective at a given time : it is necessary to verify cleanliness up to the time of putting into service. It is not possible to guarantee that installations will be absolutely free from defects and 100% clean. It is, however, possible by observing the provisions of this code to construct safe installations. However, whatever the level of such selection of components and methods of construction, if the installation is not kept clean during operation and maintenance, its reliability will be poor. In order to achieve acceptable cleanliness it is necessary to define : contaminate levels of cleanliness methods of cleaning methods of protection procedures for construction methods of inspection supervision for the prevention of contamination. Standards with regard to the level of cleanliness and the method of inspection are generally difficult to apply. It is easy to set theoretical levels which cannot be measured or achieved in practice, however, this code gives a basis for guidance. See 2.3.8. Methods of cleaning are numerous. The purpose of this section is to list the methods that may be contemplated and provide guidance in order to make the best selections.
2.3.0.2
Contaminants It is possible to distinguish: dust, fibres and particles hydrocarbons and organic residues water and element of the soil unusual objects During construction and maintenance, fine dust, particles and fibres can be deposited on component parts. Clean, pickled pipes will tend to corrode until they have been assembled resulting in the formation of a layer of oxide dust. Most of this dust will be removed in the final cleaning. However, there will always be a tendency for the remaining dust to be released during operation of the installation. During welding, particles such as residues from grinding, welding slag and grains of weld metal can be introduced into the pipes. Hydrocarbons and other organic residues may result from: oils used during manufacture of the pipes protective oils and greases machining oils lack of precautions and supervision various deposits during cleaning operations contamination of oil and grease spillage from plant and machinery Water and elements from the soil (earth, stones, etc) may be introduced into the pipelines during construction if the precautions are not observed. The consequences of water contamination may be the formation of thick layers of oxides.
1982
Page 19 of 30
IGC
In addition to the soil elements mentioned above, unusual objects are occasionally met with, such as : elements of components (parts, bolts, washers, seals) welding electrodes sealing plugs or sachets of dehydrating products hand tools oily or dry rags various site elements or objects clothing and footwear miscellaneous objects (cigarettes, etc) 2.3.0.3 Object and nature of cleaning The presence of impurities such as oil or grease, filings or chips, slag, weld spatter, textile debris, loose residue from pigs, sand and other foreign bodies of all kinds in a system containing oxygen may be the cause of ignition, explosion or poor mechanical operation. All such foreign bodies shall, therefore, be carefully eliminated. Cleaning implies the removal of contaminants and residues of cleaning products. Cleaning procedures generally comprise the following successive phases : preliminary cleaning degreasing cleaning rinsing neutralising drying (where required) blowing inspection and control arrangements for preservation The choice of cleaning products and procedures, and the choice of repetition of the various operations will be determined by the nature, amount and location of the impurities and according to the components or installations and their materials of construction. The choice of possible solutions is illustrated in Table X. The main methods are degreasing and cleaning with: liquid or vapour solvents hot water or steam with detergents acids or aqueous solutions of acids mechanical devices
2.3.1
Preliminary Cleaning
Before proceeding to the cleaning operations proper it is advisable to effect preliminary cleaning in order to remove the greater part of foreign bodies. This preliminary cleaning can be effected by tilting blowing, vacuum cleaning, brushing, sweeping, wiping etc.
2.3.2
2.3.2.1
Degreasing With Solvents

Products Only the solvents recommended in 2.2.2 may be used and preference will be given to those listed in 2.2.2.3. The advice given in 2.2.2.1 and 2.2.2.4 to 2.2.2.6 shall also be observed. Degreasing by immersion Degreasing can be effected by immersing and agitating the elementsin a tank containing the solvent. Agitation of the parts may be effected by an ultra-sonic generator. Degreasing by immersion is applied essentially to separate parts and components of an assembly. After verification of the cleanliness and dryness the parts shall be carefully packed or plugged according to 2.3.9.
2.3.2.2
1982
Page 20 of 30
IGC
TABLE X TYPICAL PROCEDURES FOR THE CLEANING OF PIPES / INSTALLATIONS FOR OXYGEN DISTRIBUTION
1982
Page 21 of 30
IGC
2.3.2.3
Degreasing by circulation Degreasing can be achieved by forced circulation of a flow of liquid solvent through the components or installation. When using this method, care shall be taken to ensure that all the parts to be degreased are properly reached by the flow of solvent in circulation. Care shall also be taken to ensure that the equipment used does not comprise any hoses or fittings made of rubber, neoprene, polyvinyl chloride or other organic elements that may be dissolved and entrained by the solvent used. The duration of degreasing by circulation shall be continued until the solvent emerges as clean as the new solvent put in. This method is applied mainly to assemblies that cannot be dismantled, to large size elements of pipelines, to prefabricated circuits and pipework, to sections of pipeline, etc. After verification of the cleanliness and removal of the cleaning products, all orifices of the components or of the installation must be sealed in accordance with 2.3.9. Degreasing by vaporisation This method consists of the removal of soluble organic materials from the surfaces of equipment by the cleaning action of continual condensation of solvent vapours. This method is applied mainly to the degreasing of large quantities of parts and detached components of an assembly or to equipment already assembled where internal geometry allows the easy flow of condensate. Degreasing may be considered complete when the returning condensate is as clean as the new solvent. After verification of the cleanliness dryness, all orifices of the components shall be sealed in accordance with 2.3.9.
2.3.2.4
2.3.2.5
Cleanliness of solvents During the course of the degreasing processes described in 2.3.2.2 to 2.3.2.4 it is necessary to check the cleanliness of the solvent used. For this purpose a sample of fresh solvent shall be kept for making comparisons A good reference point may be the discoloration of the solvent compared with fresh solvent. The solvent shall be discarded or regenerated when the degreasing operation no longer results in acceptable surfaces.
2.3.2.6
Elimination of solvent residue s After degreasing by solvents in accordance with the processes described in 2.3.2.2 to 2.3.2.4, particular care shall be taken to remove all residual traces of the solvent. Parts of simple shape and with all their surfaces accessible may be wiped with a clean, dry, lint free cloth or by blowing with dry, oil-free nitrogen or air. Parts that cannot be reached with a cloth (blind or small diameter holes, screw threads, grooves, corners, etc) shall be cleaned by blowing with dry, oil-free nitrogen or air. In the case of equipment or installations where the interior is not accessible, solvent residues shall be drained off through every available opening (tilting the equipment, opening purging orifices, drain holes, etc) and the whole shall be cleaned by blowing with dry, oil-free nitrogen or air until all traces of solvent residue have been removed. Solvents containing organic products or grease shall be moved by the vaporisation method. Cleaning may be considered complete when it is no longer possible to detect solvent in the blowing gas at the exit from the equipment or installation. There are in existence halogen leakage detectors which make it possible to determine whether all solvent residues have been eliminated.
1982
Page 22 of 30
IGC
2.3.3
2.3.3.1
Degreasing with Water Solutions or Steam

Methods Water or steam is given solvent properties by the addition of detergents or alkaline products such as carbonate of soda (Na 2 CO3 ). Hot water is preferred to cold water for application of the solution. by spraying the solution or steam at pressure against the surfaces to be degreased. by high speed circulation of solution inside the installations to be degreased. by immersion and agitation in the solution of the elements to be degreased.
2.3.3.2
Applications The degreasing methods using water solutions or steam may be used in certain cases as preliminary degreasing, e.g. before pickling operations (see 2.3.4). These methods are not recommended for the final degreasing of pipelines for the following reasons: good degreasing is often difficult to obtain the drying operations are very long and rarely efficient in the case of pipelines.
2.3.4
2.3.4.1
Treatment with Acid Products

Aims and effects of this treatment According to the products used, cleaning with acid is used in the following applications: Chemical pickling Temporary anti-corrosion protection for certain materials such as carbon steels. Products The products used depend upon the nature of the metal to be cleaned. They shall be selected and used in accordance with the recommendations in 2.2.3. Methods When required, this treatment will be preceded by degreasing according to the recommendations in 2.3.2 or 2.3.3. According to the shape and size of the parts or elements to be treated, one of the following methods may be employed: immersion in a tank containing the product Complete filling of the element with the product. This may be applied to pipeline elements or large vessels. Forced circulation of the products inside the elements. This method is applied to tubular components treated in series or to sections of pipeline. Care shall be taken to ensure that the product wets all the inside surfaces to be treated. Chemical pickling Chemical pickling by means of aqueous solutions of acids such as sulphuric or hydrochloric acid is applied to vessels, pipes, or prefabricated elements made of carbon or low alloy steel. It removes rust, scale and certain protective coatings. This pickling may be effected by one of the methods indicated in 2.3.4.3. The operation shall be completed by rinsing with a neutralising product or with running water until the pH value of the rinsing water at the outlet approaches that of the rinsing water at the inlet. Pickling bares the metal of the surfaces treated and thus favours its corrosion by contact with moisture. This operation shall therefore, be followed by an anticorrosion protection treatment in accordance with 2.3.4.5.
2.3.4.2
2.3.4.3
2.3.4.4
2.3.4.5
Phosphating and passivation These are treatments to retard the corrosion of surfaces that have been pickled and are applied to components, pipes, vessels etc., of carbon or low alloy steel. The operations of phosphating and passivation can be done in accordance with one of the methods indicated in 2.3.4.3.
1982
Page 23 of 30
IGC
After passivation the elements shall be drained and dried either by wiping with a clean, lint free cloth or by blowing with dry, oil-free nitrogen or air. TABI.E XI TYPICAL EXAMPLE OF DECREASING AND CLEANING TREATMENTS OPERATION PRODUCT TEMPERATURE DURATION OF PROCEDURE OF PRODUCT OPERATION in in C minutes LIQUID Chlorinated solvent (1) Degreasing by Alkali bath 15% aqueous solution of Na 2 CO2 Plus 0.5% detergent Rinsing Chemical pickling running water 10% aqueous solution of sulphuric acid Running water Aqueous solution of phosphoric acid (concentration acc. To manufacturers instruction) Aqueous solution of copper, chromium sodium etc salts (concentration acc. To manufacturers instructions) Dry, oilfree nitrogen or air ambient 60 to 70 Duration acc. To temperature of product (see manufacturers instructions) until initial pH is reached 60 to 90 circulation Immersion or circulation Circulation Immersion or circulation 70 to 80 30 to 40 according to 2.2 ambient 10 to 15 Immersion or circulation
Rinsing Phosphating
Ambient 70 to 80 May also be done with a composite product
Until initial pH is reached 20
Passivation
70
15
Drying
ambient
Until completely dry
blowing
(1)
To be followed by drying operation (not rinsing) before continuing with next operation.
Surfaces treated in this way have a uniform greyish colour, occasionally with some reddish-brown lights due to deposits of salts of the passivation products. Any blackish deposit forming extra thickness and slightly sticky to touch, shows that draining after phosphating and passivation has been incomplete. Whitish surfaces with a tendency to be floury indicate incomplete drying. If elements treated in this manner are not used immediately, they shall be sealed or packed according to the recommendations in 2.3.9.
1982
Page 24 of 30
IGC
2.3.4.6
Duration of treatments The duration of treatments of pickling, phosphating, etc., varies according to the state of the surfaces to be treated, the temperature, concentration and nature of the products used. It is advisable to follow the instructions supplied by the manufacturers of the products. Table XI gives an example of the application of these treatments
2.3.5
2.3.5.1
Mechanical Cleaning
Processes and applications Mechanical cleaning is generally used as a means of preliminary cleaning but some processes such as sandblasting can be used as a complete cleaning process. Cleaning can be carried out by blasting (sanding, shot-blasting) by metallic brushing and scraping, by grinding, etc. This cleaning may be done manually or with the aid of more sophisticated equipment, according to the shape, number and size of the components to be cleaned. Products and equipment The products and equipment to be used are those recommended in 2.2.4. Manual methods The accessible surfaces of parts and components of small size can be brushed to remove solid contaminants, dust, etc. Accessible welds can be ground and brushed to remove slag or excess weld metal etc. Sand and shot-blasting Sand and shot-blasting are used to remove scale, rust, varnishes, paints, manufacturing lubricants and other foreign bodies. These operations may be applied to pipes, prefabricated pipework, components and vessels. Cleaning by sandblasting is effective for the removal of certain bituminous varbishes deposited on the inside of elements of pipelines such as commercial bends, caps or tees. Chemical agents may be incapable of dissolving these bituminous varnishes. For the internal sandblasting of pipes or vessels it is recommended that a quality equivalent to the scale N9, rugotest No.3. of 1.S.O. 2632 be achieved. The abrasives and propellant gases used for this work shall be those recommended in 2.2.4.1 and 2.2.4.2. Sand or shot~blasting may be followed by anticorrosion protection according to 2.3.4.5.
2.3.5.2 2.3.5.3
2.3.5.4
2.3.5.5
Passage of cleaning pigs Preliminary cleaning of a pipeline or section of pipeline may be effected by means of cleaning pigs in accordance with the recommendations of 2.2.4.4. The propellant gas shall be clean, dry, oil-free nitrogen or air. The flow should be regulated so as to obtain a steady advance rate of the pig in the order of 2 to 3 m/s. Several successive passages of the pig shall be effected until it is found by visual observation that it no longer brings out solid bodies, particles and excessive dust at its point of exit. Only one pig at a time shall be introduced into the pipeline
1982
Page 25 of 30
IGC
2.3.5.6
Blowing out the pipelines Blowing out of the pipelines shall be done with clean, dry, oil-free nitrogen or air in accordance with the recommendations of 2.2.5. The pressure of the blowing gas may be low (close to atmospheric pressure) but its velocity shall be high. In order to be effective, i.e. to remove most of the residual dust and particles, the blowing gas shall have a minimum velocity of the order of 25 to 30 m/s. To obtain these velocities in all parts of the pipeline to be cleaned, several methods may be used: a) b) A turbocompressor delivery directly into the pipeline for cleaning at a pressure of several bar. Filling a previously cleaned section of pipeline of approximately the same length as the section to be cleaned with the gas. The pressure of this gas shall be high enough to give the velocities required when it is discharged into the section to be cleaned.
This method requires previous strength testing of the pipeline serving as storage vessel. In the case of small auxiliary pipelines of small diameter it is possible to use nitrogen supplied direct from mobile gas containers such as cylinders, bundles, etc. The duration of blowing depends upon the length of pipeline to be cleaned, the velocity of the gas, the amount of dust present, etc. Blowing should continue until the outgoing gas is free from particles and excessive dust at its point of exit. Temporary equipment and connections used for blowing shall be previously cleaned and degreased in the same way as equipment intended for use with oxygen. c) 2.3.5.7 Vacuum cleaning Vacuum cleaning can also be used either alone or in conjunction with other mechanical cleaning processes.
2.3.6
2.3.6.1
Cleaning of Components and Equipment

Cleaning of components Parts and components made of carbon or low alloy steel shall be subjected to the following treatments and in the order listed: a) b) c) Any necessary prescribed strength tests Degreasing according to the recommendations of 2.3.2 or 2.3.3. If necessary, chemical pickling according to 2.3.4.4 or mechanical cleaning according to 2.3.5.4.
d) If necessary, anticorrosion protection treatment according to 2.3.4.5. The nonferrous parts of components or items of equipment shall also be degreased in accordance with the recommendations of 2.3.2. In the case of non-metallic parts care shall be taken to select a solvent that does not attack the object to be cleaned. Assembly of the components shall then be effected in a clean environment by personnel duly informed of the cleanliness demanded. Care shall be taken not to introduce any foreign body or impurity into the component during assembly. If the component is lubricated it shall be effected in the course of assembly and shall comply with the recommendations of 2.2.1 and 3.6.0. Certain design of components require degreasing of the complete assembly in accordance with 2.3.2. After assembly, equipment or components shall be sealed or packed in accordance with the recommendations of 2.3.9.
1982
Page 26 of 30
IGC
2.3.6.2
Cleaning prefabricated pipework Carbon steel pipework designed to connect the various parts of an installation, prefabricated in the factory or fabricated on site, shall be subjected to the following treatment and in the order listed: a) b) c) Any necessary prescribed strength tests. Degreasing according to the recommendations of 2.3.2 or 2.3.3. If necessary, chemical pickling according to 2.3.4.4 or mechanical cleaning according to 2.3.5.4.
d) If necessary, anticorrosion protection treatment according to 2.3.4.5. If these elements are not fitted immediately they shall be sealed according to the recommendations of 2.3.9. 2.3.6.3 Cleaning the pipes Carbon steel pipes intended for the construction of pipelines may, after the prescribed strength tests, be treated at the factory by one of the following methods: a) Mechanical cleaning (sandblasting) according to 2.3.5.4 followed by blowing with clean, dry, oil-free nitrogen or air. b) Mechanical cleaning (sandblasting) according to 2.3.5.4 followed after b lowing by anticorrosion protection treatment according to 2.3.4.5. c) Degreasing according to section 2.3.2 or 2.3.3 followed by chemical pickling and anticorrosion protection treatment according to 2.3.4. In every case, the pipes shall, after inspection and verification of their cleanliness according to 2.3.8, be carefully sealed according to the recommendations of 2.3.9. If the pipes afterwards undergo an external coating operation care shall be taken to ensure that the sealing of the pipe cannot possibly be perforated or removed in the course of this work. Stainless steel and copper alloy pipes shall be decreased according to the recommendations of 2.3.2 and, after inspection and verification according to 2.3.8, they shall be carefully sealed according to 2.3.9.
2.3.7
2.3.7.1
Cleaning the Pipelines

Methods The method of cleaning a pipeline depends essentially upon the method of construction. From the point of view of cleaning there are two main methods of constructing a pipeline to be considered : a) Construction of the pipeline using unclean pipes. Laying shall then be followed by extensive cleaning see 2.3.7.2. b) Construction of the pipeline using clean pipes treated according to 2.3.6.3, care being taken to avoid introduction into the pipeline during laying of any foreign bodies or impurities. See 2.3.7.3. The first method makes installation easier but final cleaning will be onerous and its efficiency difficult to control. The second method, which is preferable, requires more carefully controlled laying but final cleaning is easier. The pipeline shall be cleaned before components and equipment are fitted. In the event of preassembly of components into the pipeline, they must be removed before the cleaning operations.
1982
Page 27 of 30
IGC
2.3.7.2
Pipelines constructed with unclean pipes A pipeline constructed with unclean pipes requires cleaning with very special care and attention. Such operations will be difficult to control since effective inspection is not possible. Cleaning may be effected, after the passing of a cleaning pig (see 2.3.5.5) in the following ways: a) By successive filling and circulation, by means of pumps supply and evacuation tanks, using degreasing, pickling, rinsing, phosphating and passivating products, see 2.3.4. b) By circulation of a train of the above products, separated from each other by pistons or balloons and propelled by the pressure of clean, dry, oil-free nitrogen or air. Both methods require subsequent drying hat is difficult to achieve. This may be successfully achieved in certain special cases where large quantities of blowing gas are available for drying the pipeline (e.g. availability of a turbocompressor). c) By sand blasting of the line using clean, dry, oil-free air or nitrogen with sand on the sections of 3 to 5 kilometres. This operation shall be followed by vigorous blowing to remove all sand and dust. See 2.3.5.4. Pipelines constructed-with clean pipes If the pipeline has been constructed: with pipes cleaned in accordance with 2.3.6.3 delivered sealed on site ; and if during laying every precaution has been taken according to 4.3.13 to prevent the introduction of foreign bodies and other impurities into the pipeline ; one of the following methods of final cleaning may be used : a) passage of pigs followed by high velocity blowing out with clean, dry oil-free nitrogen or air. See 2.3.5.5 and 2.3.5.6. b) blowing out with clean, dry, oil-free nitrogen or air. See 2.3.5.6.
2.3.7.3
2.3.8
2.3.8.1
Level of Cleanliness and Control

General Contamination by dust, fibres and particles can be evaluated by counting the quantity (mass or number) per unit volume for a fluid or per unit area for a system. These particles can then be classified as a function of their dimensions and of their nature.
2 Oily or organic deposits are measured in mass of deposit per unit area (mg/m ). Sophisticated methods of control can be applied during trials or tests, e.g. to determine the efficiency of a cleaning operation. on the other hand these methods are not practical in the construction workshop or on site; their efficiency is doubtful. We shall indicate in the following sections some levels of contamination and practical means of control to be employed.
2.3.8.2
Control of cleanliness Control of the absence of foreign bodies, particles filings, dust, textile waste, etc., during construction shall be effected by visual inspection with white light. Cleanliness shall be considered adequate if no trace of impurities can be detected visually. This method shall be applied to all surfaces accessible to vision, possibly with the help of a set of mirrors. Where a completed pipeline cannot be checked visually, cleanliness can be verified by absence of particles and dust during blowing operation. See 2.3.5.6.
1982
Page 28 of 30
IGC
2.3.8.3
Direct control of degreasing Visual inspection according to 2.3.8.2 is not adequate for verification of the absence of residues of oil or grease. One or both of the direct methods below may be used:a) Wipe test, lightly rubbing highly porous paper (e.g. cleansing paper) over the surface to be controlled. No permanent stain resulting from the presence of oil or grease on the surface shall show on this paper. b) Inspection of the surfaces to be controlled by ultra-violet lamp producing radiation of a wavelength between 2500 and 4000. No fluorescence betraying the presence of oil or grease or textile fibres is acceptable. NB: We draw the readers attention to the fact that some oils and greases are not fluorescent under ultra-violet light.
2.3.8.4
Indirect control of degreasing In certain cases it will be possible to use indirect methods such as solvent extraction. This method consists in rinsing the inside of the cleaned equipment with a clean solvent and evaporating a representative sample of the solvent used, then comparing the residues thus obtained with those obtained from the same quantity of clean solvent. The difference in weight between these two residues and the amount of solvent used to make it possible to calculate the quantity of impurities extracted per square metre of surface cleaned. In current technical literature figures of permissible hydrocarbons uniformally distributed vary 2 between 50 to 1000 mg/m depending upon the type of hydrocarbons. This control by solvent extraction is restricted by the difficulty in the solvent reaching and dissolving the impurities present. This method is only valid for defining the effectiveness of a cleaning process. It is not generally practical for the systematic control of cleanliness in a manufacturing workshop or on a work site. Methods of inspection The criteria for cleanliness and control shall be specified between the manufacturer and buyer. The buyer shall from the start and periodically afterwards visit the premises of the manufacturer and verify the methods of control and achievement of cleanliness specified. The manufacturer shall make a record indicating for each item of equipment: its designation and serial number the processes used for,cleaning and inspection the dates and results of inspection
2.3.8.5
2.3.9
2.3.9.1
Preservation of the Cleanliness Obtained

General After cleaning and inspection, the elements or components shall be protected from any contamination or deterioration during the time of storage and transport until they are fitted or put into service in the installations. Protection shall be assured against exposure to adverse weather and moisture. Packaging and sealing used for this purpose shall : be strong, clean and free from oil or grease be dust tight and waterproof
2.3.9.2
Packaging of small items Small items of equipment and spare parts shall be packed in sealed plastic bags. If these small items comprise orifices, these should first be sealed by means of metal, plastic or rubber plugs. Sealing with adhesive tape shall be avoided. Packing under vacuum is permitted.
1982
Page 29 of 30
IGC
2.3.9.3
Sealing of components and sections of pipework The opening of components and prefabricated pipework shall be sealed by means of blind flanges, metal, plastic or plywood covers Small orifices shall be sealed by means of metal, plastic or rubber plugs.
2.3.9.4
Sealing pipes The pipes or sections of pipework without flanges, cleaned in accordance with 2.3.6.3 shall be sealed by means of plastic plugs or caps. These may : have a conical part fitted by insertion (plug) have an external collar securely held (Cap) have force fit outer and inner lips, clamped and held by strong adhesive tape (see fig.12). For typical example.
2.3.9.5
Drying agents In order to adsorb moisture inside the packed or sealed items of equipment or components, drying agents should be used in accordance with the recommendations of 2.2.6. Inerting Equipment and components of large internal volume may be protected from internal corrosion by being inerted with a nitrogen atmosphere. Labelling Parts and packages shall carry inscriptions such as: CLEANED FOR OXYGEN SERVICE OXYGEN - NO OIL OR GREASE DO NOT OPEN BEFORE TAKING INTO SERVICE INERTED WITH NITROGEN
2.3.9.6
2.3.9.7
1982
Page 30 of 30
IGC
IGC 13/82 The Transportation and Distribution of Oxygen by Pipeline Part 3 : Equipment
The Transportation and Distribution of Oxygen by Pipeline Part 3 : Equipment
IGC 13/82/E
1982
Page 1 of 30
IGC
SECTION 3 : EQUIPMENT.................................................................................................................................................6 3.1 GENERAL ....................................................................................................................................................................6 3.1.1 Specifications.......................................................................................................................................................6 3.1.2 Invitations to Tender and Purchase Orders....................................................................................................6 3.1.3 Manufacture .........................................................................................................................................................6 3.1.4 Inspection and Acceptance ................................................................................................................................6 3.2 PIPES............................................................................................................................................................................7 3.2.0 General Considerations......................................................................................................................................7
3.2.0.1 3.2.0.2 3.2.0.3 3.2.0.4 3.2.0.5 Choice of materials ........................................................................................................................................7 Use of carbon steel pipes ...............................................................................................................................7 Use of copper or copper alloy pipes ..............................................................................................................7 Use of stainless steel pipes .............................................................................................................................7 Thickness of pipes ..........................................................................................................................................7 General provisions .........................................................................................................................................7 Method of Manufacture .................................................................................................................................7 Appearance and dimensions ..........................................................................................................................8 Pipe ends ........................................................................................................................................................8 Inspection of materials and pipes ...................................................................................................................8 Pressure test at the manufacturers ..................................................................................................................8 Internal treatment and sealing ........................................................................................................................8 External coating and wrapping ......................................................................................................................8 Markings ........................................................................................................................................................8 Handling.........................................................................................................................................................9 General provisions .........................................................................................................................................9 Manufacture ...................................................................................................................................................9 Appearance and dimensions ..........................................................................................................................9 Pipe ends ........................................................................................................................................................9 Inspection of pipes .........................................................................................................................................9 Pressure test at the manufacturers ..................................................................................................................9 Internal treatment and sealing ........................................................................................................................9
3.2.1
Carbon and Low Alloy Steel Pipes...................................................................................................................7
3.2.1.1 3.2.1.2 3.2.1.3 3.2.1.4 3.2.1.5 3.2.1.6 3.2.1.7 3.2.1.8 3.2.1.9 3.2.1.10
3.2.2
Copper Pipes........................................................................................................................................................9
3.2.2.1 3.2.2.2 3.2.2.3 3.2.2.4 3.2.2.5 3.2.2.6 3.2.2.7
3.2.3 3.2.4
Copper Alloy Pipes..............................................................................................................................................9 Stainless Steel Pipes............................................................................................................................................9

General provisions .........................................................................................................................................9 Methods of manufacture ..............................................................................................................................10 Appearance and dimensions ........................................................................................................................10 Pipe ends ......................................................................................................................................................10 Inspection of materials and pipes .................................................................................................................10 Pressure test at the Manufacturers ...............................................................................................................10 Internal treatment and sealing ......................................................................................................................10 Markings ......................................................................................................................................................10 Handling.......................................................................................................................................................11
3.2.4.1 3.2.4.2 3.2.4.3 3.2.4.4 3.2.4.5 3.2.4.6 3.2.4.7 3.2.4.8 3.2.4.9
3.3 STANDARD PIPE FITTINGS......................................................................................................................................11 3.3.0 General Considerations................................................................................................................................... 11

3.3.0.1 3.3.0.2 3.3.0.3 3.3. 0.4 3.3.0.5 3.3.0.6 3.3.0.7 3.3.0.8 3.3.0.9 Definitions....................................................................................................................................................11 Materials .......................................................................................................................................................11 Thickness .....................................................................................................................................................11 Ends..............................................................................................................................................................11 Appearance and dimensions ........................................................................................................................11 Tests .............................................................................................................................................................11 Internal treatment.........................................................................................................................................11 Inspection .....................................................................................................................................................11 Markings ......................................................................................................................................................11 General.........................................................................................................................................................12
3.3.1 3.3.2 3.3.3 3.3.4
Bends................................................................................................................................................................... 12 Reducers............................................................................................................................................................. 12 Pipe Caps or Dished Ends .............................................................................................................................. 12 Tees and Other Branches ................................................................................................................................ 12
General.........................................................................................................................................................12 Forged tees ...................................................................................................................................................12
3.3.1.0
3.3.4.0 3.3.4.1
1982
IGC
3.3.4.2 3.3.4.3
Reinforced branches .....................................................................................................................................13 Fabricated Tees ............................................................................................................................................13
3.4 A SSEMBLY COMPONENTS......................................................................................................................................13 3.4.0 General Considerations................................................................................................................................... 13

3.4.0.1 3.4.0.2 3.4.0.3 3.4.0.4 3.4.0.5 Definitions....................................................................................................................................................13 Gaskets and jointing materials .....................................................................................................................13 Leak-tightness ..............................................................................................................................................13 Mechanical strength .....................................................................................................................................13 Cleanliness ...................................................................................................................................................13 General.........................................................................................................................................................13 Standarisation...............................................................................................................................................13 Flange selection............................................................................................................................................14 Materials for weldneck flanges ....................................................................................................................14 Materials for other types of flanges .............................................................................................................14 Conditions of use .........................................................................................................................................14 Flange faces .................................................................................................................................................14 Inspection .....................................................................................................................................................14 Nuts and bolts ..............................................................................................................................................14 Bonding ........................................................................................................................................................14 General.........................................................................................................................................................15 Materials .......................................................................................................................................................15 Leak-tightness of screw threads...................................................................................................................15 Leak-tightness of couplings .........................................................................................................................15 Couplings with conical or spherical contact surface....................................................................................15 Flared tube couplings ...................................................................................................................................16 Olive couplings ............................................................................................................................................16 Flat seal or O-ring seal couplings ................................................................................................................16 Connection of couplings to pipework..........................................................................................................16
3.4.1
Flanges ............................................................................................................................................................... 13
3.4.1.0 3.4.1.1 3.4.1.2 3.4.1.3 3.4.1.4 3.4.1.5 3.4.1.6 3.4.1.7 3.4.1.8 3.4.1.9
3.4.2
Couplings........................................................................................................................................................... 15
3.4.2.0 3.4.2.1 3.4.2.2 3.4.2.3 3.4.2.4 3.4.2.5 3.4.2.6 3.4.2.7 3.4.2.8
3.5 M ISCELLANEOUS A CCESSORIES............................................................................................................................16 3.5.1 Flexible Pipes.................................................................................................................................................... 16

3.5.1.0 3.5.1.1 3.5.1.2 3.5.1.3 General.........................................................................................................................................................16 Possible uses ................................................................................................................................................16 Materials .......................................................................................................................................................17 Inspection and testing...................................................................................................................................17 General.........................................................................................................................................................17 Use of expansion elements ...........................................................................................................................17 Expansion Loops..........................................................................................................................................17 Expansion Bellows .......................................................................................................................................18 Silencers .......................................................................................................................................................18 Sound insulation coverings ..........................................................................................................................18
3.5.2
Expansion Elements ......................................................................................................................................... 17
3.5.2.0 3.5.2.1 3.5.2.2 3.5.2.3
3.5.3
Elements to Reduce Noise............................................................................................................................... 18
3.5.3.1 3.5.3.2
3.5.4 Other Accessories ............................................................................................................................................. 18 3.6 COMPONENTS..........................................................................................................................................................18 3.6.0 General Criteria for the Design and Construction of Components......................................................... 18
3.6.0.1 3.6.0.2 3.6.0.3 3.6.0.4 3.6.0.5 3.6.0.6 3.6.0.7 3.6.0.8 3.6.0.9 3.6.0.10 3.6.0.11 3.6.0.12 3.6.0.13 3.6.0.14 3.6.0.15 Compliance of components with this code ..................................................................................................18 Choice of safety factors ...............................................................................................................................18 Recommended materials ..............................................................................................................................19 Non-metallic materials .................................................................................................................................19 Metallic parts facing the gas flow................................................................................................................19 Components subjected to a differential pressure .........................................................................................19 Electrical potential - conductor....................................................................................................................19 Electrical devices .........................................................................................................................................19 Hydrostatic testing .......................................................................................................................................19 Internal surface treatment.............................................................................................................................19 Internal Cleanliness......................................................................................................................................19 Degreasing ...................................................................................................................................................19 Lubrication ...................................................................................................................................................19 Connections..................................................................................................................................................20 Sealing and packing .....................................................................................................................................20 Compliance of components with this code ..................................................................................................20
3.6.1
Stop Valves......................................................................................................................................................... 20
3.6.1.1
1982
IGC
3.6.1.2 3.6.1.3 3.6.1.4 3.6.1.5 3.6.1.6 3.6.1.7 3.6.1.8 3.6.1.9 3.6.1.10 3.6.1.11 3.6.1.12 3.6.1.13 3.6.1.14 3.6.1.15 3.6.1.16 3.6.1.17 3.6.1.18 3.6.1.19 3.6.1.20 3.6.1.21 3.6.1.22
Use of valve .................................................................................................................................................20 Internal profiles ............................................................................................................................................20 Leak tightness ..............................................................................................................................................20 Non-metallic sealing ....................................................................................................................................20 Equalising valves .........................................................................................................................................20 Quarter turn valves .......................................................................................................................................20 Manual operation .........................................................................................................................................20 Lubrication of manual operating devices .....................................................................................................21 Position indicator.........................................................................................................................................21 Operation of manual valves .........................................................................................................................21 Servomotors .................................................................................................................................................21 Oxygen operated servomotors .....................................................................................................................21 Nitrogen or air operated servomotors ..........................................................................................................21 Electrically operated servomotors ................................................................................................................21 Hydraulically operated servomotors ............................................................................................................21 Emergency control.......................................................................................................................................21 Fail safe device.............................................................................................................................................22 Small manually operated valves ..................................................................................................................22 Small pneumatically operated valves ...........................................................................................................22 Electrically operated valves .........................................................................................................................22 Manual throttling valve ................................................................................................................................22 Definition .....................................................................................................................................................22 Compliance with this code ...........................................................................................................................23 Type of valve ...............................................................................................................................................23 Materials of construction .............................................................................................................................23 Non leaktight valve installation ...................................................................................................................23 Standby manual operation............................................................................................................................23 Fail safe device.............................................................................................................................................23 Definition .....................................................................................................................................................23 Compliance with this code ...........................................................................................................................23 Type of valves ..............................................................................................................................................23 Leak-tightness ..............................................................................................................................................23 Locking device .............................................................................................................................................23 Small non-return valves ...............................................................................................................................24 Definition .....................................................................................................................................................24 Compliance with this code ...........................................................................................................................24 Loading gas ..................................................................................................................................................24 Fail safe device.............................................................................................................................................24 Balanced valves ...........................................................................................................................................24 Leak tightness ..............................................................................................................................................24 Safety shut-off..............................................................................................................................................24 Function .......................................................................................................................................................24 Recommended materials ..............................................................................................................................25 Filter elements made from non-metallic materials ......................................................................................25 Filtration threshold .......................................................................................................................................25 Strength of filter elements ............................................................................................................................25 Instrumentation filters ..................................................................................................................................25 Function .......................................................................................................................................................25 Main types ....................................................................................................................................................25 Selection.......................................................................................................................................................26 Volume correcting devices ..........................................................................................................................26 Compliance with this code ...........................................................................................................................26 Lubrication ...................................................................................................................................................26 Bellows type.................................................................................................................................................26 Remote indication ........................................................................................................................................26 Auxiliaries ....................................................................................................................................................26 Overspeed protection ...................................................................................................................................26 Function .......................................................................................................................................................27 Compliance with this code ...........................................................................................................................27
3.6.2
Automatic Control Valves ............................................................................................................................... 22
3.6.2.1 3.6.2.2 3.6.2.3 3.6.2.4 3.6.2.5 3.6.2.6 3.6.2.7
3.6.3
Non-Return Valves ........................................................................................................................................... 23
3.6.3.1 3.6.3.2 3.6.3.3 3.6.3.4 3.6.3.5 3.6.3.6
3.6.4
Pressure Reducing Valves............................................................................................................................... 24
3.6.4.1 3.6.4.2 3.6.4.3 3.6.4.4 3.6.4.5 3.6.4.6 3.6.4.7
3.6.5
Filters.................................................................................................................................................................. 24
3.6.5.1 3.6.5.2 3.6.5.3 3.6.5.4 3.6.5.5 3.6.5.6
3.6.6
Flowmeters and Meters ................................................................................................................................... 25
3.6.6.1 3.6.6.2 3.6.6.3 3.6.6.4 3.6.6.5 3.6.6.6 3.6.6.7 3.6.6.8 3.6.6.9 3.6.6.10
3.6.7
Safety Valves - Bursting Discs........................................................................................................................ 27
3.6.7.1 3.6.7.2
1982
IGC
3.6.7.3 3.6.7.4 3.6.7.5 3.6.7.6 3.6.7.7 3.6.7.8 3.6.7.9 3.6.7.10 3.6.7.11 3.6.7.12 3.6.7.13 3.6.7.14 3.6.7.15 3.6.7.16
Operating mode............................................................................................................................................27 Lifting pressure ............................................................................................................................................27 Bursting pressure ..........................................................................................................................................27 Multiple safety devices ................................................................................................................................27 Duplication of safety devices .......................................................................................................................27 Misadjustment ..............................................................................................................................................27 Safety valve materials ..................................................................................................................................27 Disc material................................................................................................................................................27 Leak tightness of safety valves ....................................................................................................................27 Pilot devices .................................................................................................................................................27 Vent pipes ....................................................................................................................................................27 Periodic inspection .......................................................................................................................................27 Periodic replacement of disc........................................................................................................................27 Small safety valves ......................................................................................................................................28 Definition .....................................................................................................................................................28 Function .......................................................................................................................................................28 Ignition risks ................................................................................................................................................28 Compliance with this code ...........................................................................................................................28 Material in contact with oxygen...................................................................................................................28 Material not in contact with oxygen ............................................................................................................28 Insulating capability .....................................................................................................................................28 Design and installation.................................................................................................................................28 General criteria.............................................................................................................................................29 Flow limiters ................................................................................................................................................29 Pressure sensors and indicators ....................................................................................................................29 Pneumatic control device .............................................................................................................................29 Temperature sensors and indicators .............................................................................................................29 Miscellaneous items of equipment...............................................................................................................30
3.6.8
Insulating Joints................................................................................................................................................ 28
3.6.8.1 3.6.8.2 3.6.8.3 3.6.8.4 3.6.8.5 3.6.8.6 3.6.8.7 3.6.8.8
3.6.9
Other Components............................................................................................................................................ 29
3.6.9.1 3.6.9.2 3.6.9.3 3.6.9.4 3.6.9.5 3.6.9.6
1982
Page 5 of 30
IGC
SECTION 3 : EQUIPMENT
3.1 General
This section deals with recommendations concerning the design and manufacture of items of equipment and components for oxygen systems. The recommendations represent minimum requirements for the safety of oxygen systems and are intended for guidance in the preparation of fully detailed specifications by users.
3.1.1
Specifications
It is desirable for users to draw up specifications for their invitations to tender and for purchasing. The form of these document shall be related to their purpose. The documents may include requirements such as: additional specifications the type of manufacture quality cleaning procedures dimensions and tolerances inspection etc
3.1.2
Invitations to Tender and Purchase Orders

Whenever an invitation to tender is issued or an order given for equipment destined for use with oxygen, it shall specify that the equipment is intended for use with oxygen, indicating the conditions of use, (e.g. pressure, temperature, etc) and the requirements for cleanliness and degreasing. A certificate of conformity may be required of the supplier. The wording of this certificate shall be drafted at the time of ordering.
3.1.3
Manufacture
The manufacture of items of equipment and components shall comply with the recommendations of this Code and relevant Standards, and users specifications. The final assembly of components, sub-assemblies or unit parts, previously degreased and cleaned in accordance with the recommendations of 2.3.2 or 2.3.3 shall be carried out in a clean place specially provided for the purpose, by personnel duly instructed concerning the cleanliness demanded in accordance with 2.3.6 and 2.3.9.
3.1.4
Inspection and Acceptance

In spite of the recommendations and specifications made, items of equipment or components intended for use with oxygen may not conform completely to the conditions indicated in the order. Deviations such as: the use of non-recommended materials or lubricants inadequate cleaning nonobservance of dimension or tolerance errors various irregularities may occur. Inspection of equipment before its installation and commissioning is, therefore, mandatory. It is preferable for the user to carry out inspection on the suppliers premises before the equipment is despatched. The equipment shall be plugged or packed according to the recommendations of 2.3.9 and 3.6.0.15 before despatch. Plugs or packaging shall only be removed at the last moment before assembly of the equipment in the installation.
1982
Page 6 of 30
IGC
3.2
3.2.0
3.2.0.1
Pipes
Choice of materials Pipes intended for the construction of pipelines above or below ground shall be made from one of the metals recommended in section 2.1.1. The metals most frequently used are: carbon steel copper and copper alloys stainless steel Pipes of nickel or nickel alloy may be used for special applications. The use of rigid pipes of non-metallic material is forbidden for oxygen. The case of hoses is dealt with in 3.5.1.
3.2.0.2
Use of carbon steel pipes Carbon steel pipes are generally used for delivery and distribution pipelines above or below ground, and for the construction of pipework fittings. Carbon steel pipe shall not be used for vents and purges to atmosphere. Use of copper or copper alloy pipes Preference is given to copper and its alloys by reason of their resistance to oxidation and ignition, as well as of their ease of cleaning. Use of stainless steel pipes Stainless steel is characterised by greater mechanical strength than copper but its behaviour in the event of ignition is less satisfactory (see 2.1.1.1). Stainless steel pipes may be used for delivery and distribution pipelines both above and below ground and for the construction of the pipework elements of valve or delivery stations and instrument piping. Thickness of pipes The pipe thickness is determined according to the material, the size of the pipe and the design pressure selected, in accordance with the national standards and regulations in force in the country where the pipes are to be installed (see 4.1.4).
3.2.0.3
3.2.0.4
3.2.0.5
3.2.1
3.2.1.1
Carbon and Low Alloy Steel Pipes

General provisions Carbon and low alloy steel pipes shall comply with the national standards and regulations in force in the country for which they are intended and shall conform to the buyers specification. Generally speaking, the regulations, standards and specifications determine the acceptable limit of conditions and characteristics. Method of Manufacture Pipes may be manufactured by different methods : seamless welded longitudinally welded helicoidally Seamless pipes made by hot rolling shall be of one piece and no joining of short pieces of pipe will be tolerated. Any repairs by welding is prohibited. Welded pipes shall be welded without overlap along the line of contact of the edges, which may be linear or helicoidal. The edges to be welded shall be sound, free from scale and rust and dry. They shall be correctly formed and aligned, without any offset. The welding process will be agreed between vendor and user.
3.2.1.2
1982
Page 7 of 30
IGC
3.2.1.3
Appearance and dimensions Pipes shall be straight and cylindrical in shape. They shall present a uniform surface. Their dimensions (diameters and thicknesses), theoretical mass, tolerances, permissible irregularities or defects of structure and appearance shall comply with the national standards in force. Pipe ends The ends of pipes shall be trimmed and prepared at right angles to their axis. Edges shall be clean and free from burrs. The ends shall be chamfered for butt welding. No visible lamination will be tolerated. In the case of welded pipes, it may be advisable for the inside pipe welds to be bevel ground at each end for a distance of at least 50mm before delivery.
3.2.1.4
3.2.1.5
Inspection of materials and pipes The inspection of materials and pipes at the factory shall be carried out to ascertain confirmity with the users code, specification or national regulations. Pressure test at the manufacturers Before applying any coating or wrapping, all pipes shall be hydraulically pressure tested. The test pressure shall not exceed the maximum pressure compatible with the stresses permitted by the regulations or standards. The pressure shall be maintained for at least 15 seconds. No leakage or permanent deformation shall occur. Test pressures are defined in 4.1.9.
3.2.1.6
3.2.1.7
Internal treatment and sealing Pipes may undergo cleaning treatment according to 2.3.6.3, and will be sealed in accordance with 2.3.9.4 to maintain cleanliness, if dessicants are used they shall comply with 2.2.6. External coating and wrapping External coating or wrapping shall be made in accordance with the rules of the art under conditions of temperature and humidity compatible with the nature of the products. The coating shall have good adhesion, good uniformity and perfect electrical continuity, which shall be verified by testing with a detector to a minimum of 10,000 volts. The coating shall be designed to ensure an insulation value in excess of 10,000/m2 , measured on the installed pipe. The ends of pipes shall not be coated for a distance of : 160 to 200 mm for pipes of 2 and 3 nom dia 250 to 300 mm for pipes of 4 to 10 nom dia 300 to 350 mm for pipes above 10 nom dia
3.2.1.8
3.2.1.9
Markings The accepted pipes shall bear clearly visible markings conforming with the users code and specification or national regulations. In the absence of the above, the following marking is recommended at a minimum of 100 mm and a maximum of 140 mm from one end of pipe and in such a way that any coat or wrapping does not cover them. By permanent marking : the manufacturers mark (identifying the factory of manufacture) the mark of the cast the year of manufacture the identification number of the pipe the required inspection and test marking
1982
Page 8 of 30
IGC
By stencilling : Where special pipes are procured whose thickness or grade differs from the standard pipes, these shall have a clearly visible distinctive marking. No internal marking shall be permitted. 3.2.1.10 Handling In the course of transport and handling, all necessary steps shall be taken to prevent damage to pipes and their protective coatings.
3.2.2
3.2.2.1
Copper Pipes
General provisions Copper pipe shall comply with the national standards and regulations in force in the country where the pipes are to be used, and shall conform to the buyers specification. Manufacture Pipes shall be solid drawn deoxidized non-arsenical welding grade copper and may be supplied : In straight lengths, in one of the following conditions, as drawn, (unsuitable for bending or expanding unless locally annealed), annealed, quarter hard, half hard or hard. In coils, annealed Appearance and dimensions Pipes shall be straight and cylindrical in shape, Their dimensions (diameter and thickness), theoretical mass, tolerances, permissible irregularities or defects of structure and appearance shall comply with the national standards or regulations. Pipe ends The ends of pipe shall be trimmed and prepared at right angles to their axis. Edges shall be clean and free from burrs. Inspection of pipes The inspection of pipes at the manufacturers shall be carried out by a competent person, to ascertain conformity with the users specifications and national standards or regulations. Pressure test at the manufacturers All pipes shall be hydraulically pressure tested. The test pressure shall not exceed the maximum pressure compatible with the stresses permitted by the national standards or regulations. Internal treatment and sealing When specified by the user, pipes shall undergo cleaning treatment and be sealed in accordance with 2.3.6.3 and 2.3.9.4.
3.2.2.2
3.2.2.3
3.2.2.4
3.2.2.5
3.2.2.6
3.2.2.7
3.2.3
Copper Alloy Pipes

Piping made of copper alloys (e.g. cupro nickel, tin bronze, aluminium bronze) may be used for the construction of pipework elements and pipelines where their mechanical and physical characteristics allow. Generally the mechanical and physical characteristics of copper or copper alloys vary according to their composition and shall be specified by the manufacturer for each material. The use of brass pipes shall be avoided because of their tendency to crack in certain stress conditions (vibration, etc).
3.2.4
3.2.4.1
Stainless Steel Pipes

General provisions Stainless steel pipes shall comply with the National standards and regulations in force in the country for which they are intended and shall conform to the buyers specification. Generally speaking, the regulations, standards and specifications determine the acceptable limit conditions and characteristics.
1982
Page 9 of 30
IGC
3.2.4.2
Methods of manufacture Stainless steel pipes may be: seamless welded longitudinally welded helicoidally Seamless pipes made by hot rolling shall be of one piece and no joining of short pieces of pipe will be tolerated. Any repairs by welding is prohibited. Welded pipes shall be welded without overlap along the line of contact of the edges, which may be linear or helicoidal. The edges to be welded shall be sound, free from scale and dry. They shall not correctly formed and aligned, without any offset. The welding process will be agreed between vendor and user. Appearance and dimensions Pipes shall be straight and cylindrical in shape. They shall present a uniform surface. Their dimensions (diameters and thickness), theoretical mass, tolerances, permissible irregularities or defects of structure and appearance shall comply with the national standards in force. Pipe ends The ends of pipes shall be trimmed and prepared at right angles to their axis. Edges shall be clean and free from burrs. The ends shall be chamfered for butt welding.
3.2.4.3
3.2.4.4
3.2.4.5
Inspection of materials and pipes The inspection of materials and pipes at the factory shall be carried out to ascertain conformity with the users code, specification or national regulations. Pressure test at the Manufacturers All pipes shall be hydraulically pressure tested before applying any coating or wrapping. The test pressure shall not exceed the maximum pressure compatible with the stresses permitted by the regulations or standards. The pressure shall be maintained for at least 15 seconds. No leakage or permanent deformation shall occur. Test pressures are defined in 4.1.9. Internal treatment and sealing Pipes may undergo cleaning treatment in accordance with 2.3.6.3. Markings The accepted pipes shall bear clearly visible markings on the outside conforming with the users code and specification or national regulations. In the absence of the above, the following marking is recommended at a minimum of 100 mm and a maximum of 140 mm from one end of pipe and in such a way that any coat or wrapping does not cover them. By permanent marking : the manufacturers mark (identifying the factory of manufacture) the mark of the cast the year of manufacture the identification number of the pipe the required inspection and test marking By stencilling : Where special pipes are procured whose thickness or grade differs from the standard pipes, these shall have a clearly visible distinctive marking. No internal marking shall be permitted.
3.2.4.6
3.2.4.7 3.2.4.8
1982
Page 10 of 30
IGC
3.2.4.9
Handling In the course of transport and handling, all necessary steps shall be taken to prevent damage to pipes and where applicable their protective coatings.
3.3
3.3.0
3.3.0.1
Standard Pipe Fittings

Definitions The name Standard Pipe Fittings is given to pipeline elements such as bends or elbows reducer cones tees caps or dished ends weldolets etc Generally these parts are available as standard items. Materials It is generally desirable to use for pipe fittings the same grade of metal as that of the corresponding pipe. As pipe fittings made of copper alloy are special products, the potential user shall, in collaboration with the manufacturer, study the characteristics required shaped parts of equipment as a function of their intended use. Thickness The thickness required for the various parts of these elements shall comply with the standards and regulations in force as a function of the intended conditions of use.
3.3.0.2
3.3.0.3
3.3. 0.4 Ends All ends for welding shall be trimmed and prepared in a plane perpendicular to the axis of the pipe to which they are to be welded. Edges shall be clean and free from burrs. Ends for butt welding shall be bevelled. 3.3.0.5 Appearance and dimensions Dimensions, theoretical mass, tolerances, permissible irregularities or defects of structure and appearance shall comply with the national standards in force. Tests Standard pipe fittings do not generally undergo internal hydraulic testing by the manufacturers. Internal treatment No coating, covering or grease shall be tolerated on the internal surfaces of pipe fittings. Pipe fittings shall undergo cleaning treatment as indicated in 2.3.6.2 and 2.3.6.3. Inspection Inspection shall be carried out to ascertain conformity with the users code, specifications or national regulations. Markings All markings shall be on the outside of the element.
3.3.0.6 3.3.0.7
3.3.0.8
3.3.0.9
1982
Page 11 of 30
IGC
3.3.1
3.3.1.0
Bends
General Bends shall comply with the recommendation of 3.3.0 and to the relevant specifications. Bends may have different radii according to standards. These bends are made from seamless pipes. They may be 45, 90 or 180. These bends are available in various thicknesses. The thickness shall be selected as a function of the anticipated conditions of use. The use of long radius types are preferred.
3.3.2
Reducers
Reducers are defined by their large and small diameters (D and d). For any given large diameter D there is a number of reduced diameters d defined by the Standards. According to standards reducers may be of constant angle or length. Reducers may be concentric or eccentric. Reducers shall comply with the recommendations of 3.3.0 and the following : The thickness shall be selected as a function of the conditions of use. When eccentric reducers are used in a horizontal position, it shall be ensured that the straight generating line is at the bottom.
3.3.3
Pipe Caps or Dished Ends

Dished ends or pipe caps may be : or large squaring-off radius elliptical of the cap type for welding on pipes Elliptical ends and those with a large squaring-off radius are generally used in the manufacture of pressure vessels (storage tanks for gases, etc) while the cap type of end is used for pipeline elements or components. Dished ends shall comply with the recommendations of 3.3.0 and to the relevant specifications. Dished ends may be of various thicknesses. The thickness shall be selected as a function of the conditions of use.
3.3.4
3.3.4.0
Tees and Other Branches

General Branches may be made by means of : Forged tees Reinforced branches (weldolets, sweepolets, etc) Fabricated tees Welding of two pipes, making a given angle and reinforced, if required, by means of gussets or plates. It is preferable to use forged tees or reinforced branches of the weldolet, etc., type because their mechanical strength is generally better than that of branches made by the direct joining of two pipes (angled or right angle tappings). Tees and branches shall comply with the recommendations of 3.3.0 and the following.
3.3.4.1
Forged tees Forged tees may be : Equal tees, for joining a branch of the same diameter as the pipeline Reducing tees, for connecting a branch of smaller diameter The thickness shall be selected as a function of the intended conditions of use.
1982
Page 12 of 30
IGC
3.3.4.2
Reinforced branches Reinforced branches of the -olets family (weldolets, sweepolets, etc) are forged shaped parts specially designed to effect branching without the need for any supplementary reinforcement. -Olets (weldolets, sweepolets, etc) shall be selected to suit the conditions of use in accordance with the manufacturers instructions. -Olets shall only be used where the branch diameter is smaller than that of the main pipeline, otherwise the cut in the pipeline would be too large causing deformation during welding. Fabricated Tees The use of fabricated tees (angled or perpendicular) between pipes of equal diameter should be avoided. Care shall be taken in calculating and making any necessary reinforcement.
3.3.4.3
3.4
3.4.0
3.4.0.1
Assembly Components
Definitions Assembly components are defined as devices which permit connection or disconnection of pipeline elements to each other or to components. Bolted assemblies are defined as flanges, and screwed assemblies are called couplings.
3.4.0.2
Gaskets and jointing materials Gaskets and jointing materials, if they are necessary, shall be selected from the materials recommended in 2.1.4. Leak-tightness Whatever the type of assembly concerned it shall be leaktight. Any leakage may lead to ignition. Mechanical strength Flanges and couplings shall be selected as a function of the conditions of use. Cleanliness Flanges and couplings shall be cleaned and degreased. The joint faces of flanges and couplings shall not contain any trace of paint or varnish. If flanges are delivered with their joint faces protected against corrosion by a coat of varnish, this shall be removed in accordance with 2.3 before the flange is assembled into the installation.
3.4.0.3 3.4.0.4 3.4.0.5
3.4.1
3.4.1.0 3.4.1.1
Flanges
General Flange assemblies are generally used for 1 diameter (DN 25) pipes and above. Standarisation In most industrial countries there are standards that define the types of flanges, their dimensions, their characteristics and the conditions (pressure and temperature) for their use. Flanges are defined : according to their type i.e. weldneck, slip-on socket screwed and backing according to their rated pressure (see 1.1.3.2).
1982
Page 13 of 30
IGC
3.4.1.2
Flange selection The flanges preferred for use on oxygen pipelines are weld neck for butt welding. Flanges of non-standard dimensions, (special flanges) may be used for certain components. In these cases the dimensions of the flanges shall be determined by the designer of the component as a function of the metal, the type of joint and the conditions of use. Where screwed flanges are used leak tightness between flange and pipe may be obtained by : a line of welding or brazing at the back of the flange by P.T.F.E. tape in accordance with 2.1.5.
3.4.1.3
Materials for weldneck flanges Weldneck flanges shall be of weldable steel. Flanges of stainless steel or copper alloy may be used. Their dimensions shall be determined as a function of the nature of the metal, the type of joints and the anticipated conditions of use. The steel flanges of steel pipeline elements may be connected to the flanges of a stainless steel or copper alloy component. Materials for other types of flanges Materials and dimensions are selected as a function of the type of joint and condition of use in compliance with appropriate standards and recommended materials in 2.1. Conditions of use The conditions of use (pressure and temperature) of flanges are defined by the appropriate standards. Flange faces Flange faces shall be selected as a function of the nature of the gasket used. The flanges may have : a flat or raised face for use with flat or similar gaskets single or double recessing for 0 rings or annual gaskets specially shaped flange bearing surfaces for special metallic gaskets. When using flat seals on flanges without recesses, it is necessary to make sure that the seal does not project into the interior of the pipe. Inspection The appearance, dimensions, chemical analysis and mechanical testing of the materials and of the flanges shall comply with the national standards. Nuts and bolts Nuts and bolts shall comply with the relevant standards. For special flanges the nuts and bolts shall be specified by the flange designer as a function of the anticipated conditions of use. Bonding If flanges have gaskets which are electrically non-conductive, the two flanges shall be fitted and connected to each other by a bonding strip (see 4.2.5.14).
3.4.1.4
3.4.1.5 3.4.1.6
3.4.1.7
3.4.1.8
3.4.1.9
1982
Page 14 of 30
IGC
3.4.2
3.4.2.0
Couplings
General Couplings are used for : union couplings between pipes Couplings for connection to components or elements of a pipeline (male or female connections) They may be : straight elbow tee cross etc. (see fig.17) They may be used on auxiliary pipes or piping whose diameter is equal to or less than 40 mm (1.1/2"). For pipes of nominal diameter 50 mm (2) and over it is preferable to use flange assemblies according to 3.4.1. Whatever the type of coupling used it shall be fitted with care and in accordance with the instructions of the designer. The best of couplings leak if badly fitted and could become a safety risk. The effort required for tightening is dependent upon the type of coupling used. The various designs of coupling are dealt with in 3.4.2.3 to 3.4.2.7. Materials The material for couplings shall be chosen from the materials recommended in 2.1.1.2. Materials liable to produce electro chemical action shall be avoided. Couplings shall, therefore, be made of a similar material to that of the pipework to which they are fitted. Since drawn brass is subject to mechanical fracture due to possible flaws or cracking, its use is not recommended. Die-stamped or forged brass may be used. Use of cast iron shall be limited due to its low mechanical characteristics. Leak-tightness of screw threads The leak-tightness of the threads for coupling connections to a component may be made: by means of a taper thread by means of taper thread with PTFE tape according to 2.1.4.5. Fig (8b). by means of a parallel thread with a flat gasket compressed between coupling and component in compliance with materials in 2.1.4.2. by means of tinned threads. Leak-tightness of couplings Couplings are distinguished according to the methods of sealing: Couplings with metal-to-metal seal, such as a conical or spherical contact surface flared tube an olive Couplings with a seal packing such as flat gasket or O-ring For each type of coupling there is a multiplicity of patented models and selection is generally conditioned by company standards. For oxygen installations it is preferable to use metal-to-metal seal couplings. Couplings with a nonmetallic packing should be reserved for installations requiring frequent dismantling. Couplings with conical or spherical contact surface These are three piece couplings whose seal is ensured by contact between two surface lines of the connection parts. The contours of these surfaces may be : cone to cone, with different angles cone to sphere The contact surfaces shall be perfectly clean and in good condition.
3.4.2.1
3.4.2.2
3.4.2.3
3.4.2.4
1982
IGC
3.4.2.5
Flared tube couplings This type of coupling is used for relatively thin walled pipes. The seal is obtained by contact of the flare at the end of the pipe with the conical contact surface of the nipple. It is generally necessary to provide a special tool to flare the pipe correctly. Some types use a sleeve which prevents rotation of the pipe during tightening.
3.4.2.6
Olive couplings This type of coupling has a metal ring which effects limited deformation or penetration of the outer wall of the pipe to be connected. Tightening of the nut effects a seal between the olive and the pipe and between the olive and the nipple of the coupling. This coupling eliminates threading, welding or flaring of the pipe but requires careful assembly. (Strict observance of assembly instructions provided by the coupling designer). The mechanical characteristics and dimensions of the parts shall be related to the material and dimensions of the pipe and shall comply with the Manufacturers specification, Numerous types of coupling are commercially available. They generally differ only in the shape and manner of sealing effected by the olive. Flat seal or O-ring seal couplings The leak-tightness of this type of coupling is obtained by means of either a flat or an O-ring, generally fitted inside the nipple. The seal material shall be chosen from the materials recommended in 2.1.4.2. If the flat seal is of non-metallic material it shall not project into the inside of the pipe. It is preferable to use couplings with a metal seal.
3.4.2.7
3.4.2.8
Connection of couplings to pipework With the exception of flared pipe and olive type couplings, for which the pipe is directly held by tightening of the nut, the other couplings require the fitting of an adaptor on the end of the pipe. The fitting of this adaptor depends upon the pipe material, its diameter and thickness and the conditions of use. The main methods are : a) by welding b) by silver brazing c) by screw threading Leak-tightness of the screw thread can be obtained by means of either a welded or brazed silver bead or PTFE tape.
3.5
3.5.1
3.5.1.0
Miscellaneous Accessories
Flexible Pipes
General This section concerns only small diameter (25 mm and below) flexible connections of short length which are likely to be used in oxygen distribution installations dealt with in this Code. Possible uses They may be used for connecting instrumentation components to the main pipeline, for instruments that are sensitive to vibration. Generally speaking, preference will always be given to rigid metal pipelines. Flexible connections should be installed together with a safety device attached to the flexible connection to prevent dangerous whipping in case of fracture.
3.5.1.1
1982
Page 16 of 30
IGC
3.5.1.2
Materials The inner tube shall be smooth and of either copper alloy or fluorinated or chlorofluorinated resin. Hoses with corrugated inner tubes are not recommended. The outer sheath shall consist of a single or double metal braid. Additional outer sheaths of chlorinated or nitrated elastomer may be added in order to improve protection of the hose against outside influences. End fittings shall be of copper alloy or stainless steel. Drawn or turned brass shall not be allowed for hoses liable to be subjected to vibration.
3.5.1.3
Inspection and testing Flexible pipes shall be clean and degreased (see 2.3.8). They shall have undergone a hydraulic strength test at twice the maximum design pressure and also a leak-tightness test. The leak-tightness test shall be with nitrogen. With the hose submerged in a tank of water, no bubbles shall appear.
3.5.2
3.5.2.0
Expansion Elements
General At ambient temperatures the thermal expansion of mild carbon steel is of the order of 0.0117mm per degree C per metre length. Under the same conditions, the thermal expansion of copper and stainless steel is 40 to 50% greater than that of mild steel. The free thermal expansion of above-ground pipelines of carbon steel caused by the variations in ambient temperature may generally be accommodated by changes of direction of the pipeline, expansion loops or other expansion devices. The configuration of the pipeline may be designed to accommodate the movement of the pipeline or expansion loops inserted. These solutions are preferable to the use of expansion bellows. Use of expansion elements Expansion elements can be used : To compensate for thermal expansion or contraction. To prevent excessive stresses due to relative movement between parts of the installation. Where expansion elements are used care shall be taken to ensure that adequate supports, anchors and guides are fitted. Where expansion bellows are used, manufacturers design and installation instructions shall be followed. Expansion Loops Expansion loops may be made in one of the shapes below :
3.5.2.1
3.5.2.2
The radius of curvature shall be chosen to facilitate the use of cleaning pigs if required. If the loops are made on site, care shall be taken to ensure that their interior is perfectly clean and degreased after the bending and fabrication operations.
1982
Page 17 of 30
IGC
3.5.2.3
Expansion Bellows Expansion bellows are metallic elements which have been preformed, generally made of materials with a high elastic limit, comprising a certain number of corrugations which allow variations of their length (axial movement fig. 14) or lateral movements or a combination of both.
Expansion bellows shall be of entirely metallic construction and made of the metals recommended in 2.1.1. They shall have a smooth inner sleeve to reduce turbulence and dust accumulation. Before assembly of the sleeve, the inside of the corrugations shall be inspected for cleanliness.
3.5.3
3.5.3.1
Elements to Reduce Noise

Silencers Silencers are components which make it possible to reduce the noise of a gas flow by using baffle plates to cause expansion of the gas in stages. Shells and baffles of silencers shall be entirely of metallic construction, made from the metal recommended in 2.1.1. The assembly should be designed and made to avoid any relative movement of the parts. If silencers make use of sound-absorbing materials, these shall be non-greasy and non-combustible, such as glass fibre or mineral wool (see 2.2.8.5). Silencers may be used for venting systems. Sound insulation coverings The reduction of noise from a pipeline and its components may be achieved by means of an outer covering. The insulating material shall be non-greasy and non-combustible such as glass fibre or mineral wool. Care shall be taken to prevent any moisture ingress through the insulation to the pipe resulting in corrosion.
3.5.3.2
3.5.4
Other Accessories
Any other accessory liable to come into contact with oxygen shall be designed and made in the spirit of the recommendations of this Code, from materials recommended in 2.1 and fitted clean and degreased in accordance with the recommendations of 2.3.
3.6
3.6.0
3.6.0.1
Components
General Criteria for the Design and Construction of Components
Compliance of components with this code The design manufacture and supply of all components described in 3.6.1 to 3.6.9 shall conform with the general criteria stated in 3.6.0. Choice of safety factors Safety factors of design used for other non-flammable and non-corrosive gas applications are also valid for oxygen components and pipes. Higher safety factors are recommended for some items of equipment which are particularly sensitive to external stresses - such as, rotary meters. Components of a higher rating class or PN, may then be fitted for a given rated operating pressure providing additional thickness and resistance to deformation which also improves resistance to ignition.
3.6.0.2
1982
IGC
3.6.0.3 3.6.0.4
Recommended materials Components may be manufactured only from the suitable materials in 2.1. Non-metallic materials Parts made of non-metallic materials (e.g. gaskets, valve seats, etc) shall have the minimum possible mass. Parts made of non-metallic materials shall be dense, non porous and free from surface or other defects. Compacted fibres and powders shall be excluded. These parts shall be securely enclosed with the minimum of play in solid metallic supports which are good conductors of heat (e.g. copper alloys). Parts made of non-metallic materials should preferably not face the gas flow.
3.6.0.5 3.6.0.6
Metallic parts facing the gas flow Metallic internal parts which may face the gas flow should preferably be of copper base alloys. Components subjected to a differential pressure Any part of a component subjected to a differential pressure shall withstand the maximum value which this pressure could attain (for filters see 3.6.5). Electrical potential - conductor When two or more metallic elements are likely to be electrically insulated by non-metallic materials, these components shall be brought to the same electrical potential by efficient and permanent conductors (metal braiding, springs, etc). This paragraph does not apply to insulating joints as defined in 3.6.8. These conductors shall not be detachable from the outside of the valve (or without dismantling the valve). Electrical devices Electrical contacts shall not be located within components pressurised with oxygen unless they are contained within an enclosure which prevents the entry of oxygen. Hydrostatic testing To hollow bodies of components subject to pressure shall be subjected to hydrostatic test at the manufacturers works and under his responsibility. In most countries legal regulations give the test conditions for pressure vessels.
3.6.0.7
3.6.0.8
3.6.0.9
3.6.0.10 Internal surface treatment The internal metal walls of components of carbon steel, alloy or low alloy steel, shall be treated to remove scale and rust according to 2.3.6. Furthermore, it is recommended that further oxidation be prevented by metallic coating or by dry phosphating. The recommended descaling products are those stated in 2.2.3. 3.6.0.11 Internal Cleanliness The inside of components shall be clean and shall not contain any trace of paint or varnish. All parts which are likely to come into contact with oxygen shall be kept free from any trace of oil or grease. This degree of cleanliness shall be maintained throughout all transportation, storage and assembly operations. 3.6.0.12 Degreasing Degreasing shall be carried out with one of the solvents recommended in 2.2.2 according to recommendations of 2.3.2 or 2.3.3. Only new solvents or those purified by distillation may be used. After degreasing no trace of the solvents or deposits shall remain the component. 3.6.0.13 Lubrication All components should be designed to function without lubrication. However, if a lubricant is necessary to permit assembly operations or the functioning of a component, it shall be selected from the lubricants authorised in 2.2.1 and distributed on the surfaces to be lubricated. Its use shall be kept strictly to a minimum. The lubricant shall be incorporated for life when the component is assembled and no trace shall be discernible from the outside. A deviation is permitted in the case of components where experience and comprehensive testing has demonstrated the safe use of such components.
1982
Page 19 of 30
IGC
3.6.0.14 Connections The components may be provided with flanges (standardised or special) screwed connections or welding stubs for assembly into the pipelines. Welding stubs shall have the same internal dimensions (within tolerances permitted by relevant codes) as the corresponding pipelines and have compatible characteristics. (see 3.4). If coupling flanges are used care shall be taken that electrical continuity between the component and the adjacent pipeline is permanently assured. 3.6.0.15 Sealing and packing Components shall be supplied by the manufacturer with all orifices tightly plugged and sealed. If the inside contains sachets of a dehydrating product it shall be of a type stated in 2.2.6 and shall be clearly visible and integral with the sealing device of the largest orifice. The external face of the flanges shall not bear any trace of varnish, grease or paint. The exterior of the body of the components may be painted and shall bear the clearly visible inscription : OXYGEN and Degreased for Oxygen Service. Packing shall be designed to protect the components against damage and shock. For preservation of cleanliness see 2.3.9.
3.6.1
3.6.1.1
Stop Valves
Compliance of components with this code Stop valves may be manually or power operated (see 3.6.1.10 to 3.6.1.18). Their design shall comply with 3.6.1.0 and the following requirements. Use of valve A stop valve shall not be used for regulating the flow. It shall be fully open or closed. When it is fully open it is highly recommended that the non metallic parts do not face the impact of gaseous flow. Internal profiles The design of the component should be simple and present the smoothest flow profile possible to reduce turbulence. Diaphragm or spherical plug valves may be of the full flow type (without a reduction in the cross section of the passageway through the valve) or the reduced flow type (in the form of venturi). In the latter case, it shall be ensured in operation that in the reduced cross section the maximum flow velocity of the gas remains in accordance with the regulations of 4.1.2.4. This is also applicable to stop valves of the piston or butterfly types in which the moving parts often obstruct a part of the cross section of the passageway. Leak tightness All stop valves shall be designed so as to ensure the maximum leak tightness when in the closed position. Non-metallic sealing The ratio of the mass of the non-metallic materials directly affecting the leak tightness of the valve to the total mass (flanges included) of the valve should be the lowest possible. Equalising valves The opening of certain valves may be facilitated by preliminary equalising the pressures acting on either side of the closure element. The design, construction and operation of the pressure equalising valve shall conform with the recommendations of 3.6.0 and 3.6.1.19 to 21. Quarter turn valves So-called quarter turn valves (rotary plug valves, butterfly valves) with a passageway diameter equal to 50 mm or over shall be provided with a reduction gear and wheel requiring several complete turns of the operating wheel to completely open the valve. Manual operation Manual operation of the valves shall comply with the provisions of 3.6.1.9 to 3.6.1.11.
3.6.1.2
3.6.1.3
3.6.1.4
3.6.1.5
3.6.1.6
3.6.1.7
3.6.1.8
1982
Page 20 of 30
IGC
3.6.1.9
Lubrication of manual operating devices If the mechanical device transmitting movement from the operating wheel to the moving part of the valve, (bevel gear, worm gear, reduction gear, etc) requires lubrication, this shall be used in minimum quantity and be one of the products stated in 2.2.1. In this case, the kinetic transmission mechanism shall preferably be enclosed and shall not be subjected to the gas pressure. If there is a possibility of the oxygen moving towards the housing containing the lubricated mechanism, this housing shall be provided with a pressure limiting device.
3.6.1.10 Position indicator All manual valves larger than 40 mm shall include a simple device which locally indicates the position of the closure element. 3.6.1.11 Operation of manual valves Manual valves and actuators shall be designed for easy operation preferably by one person. 3.6.1.12 Servomotors The valve may be operated by means of a servomotor which may be one of the following : pneumatic servomotors using oxygen pneumatic servomotors using dry oil-free compressed air or nitrogen electrical servomotors hydraulic servomotors Whatever type of servomotor is used the mechanism shall conform with the provisions of 3.6.1.9 and 3.6.1.10 relating to manual operation. Where servomotors are fitted to stop valves in which an equalising valve cannot be included and where fast opening of the valve could result in a hazardous condition the servomotor shall be designed to operate the valve slowly on initial opening. 3.6.1.13 Oxygen operated servomotors If a pneumatic servomotor uses oxygen as the driving fluid the construction of the moving device (for example the ram : piston and cylinder assembly, etc) shall conform with the provisions of 3.6.0. If the driving fluid is oxygen taken from the pipeline network, two possibilities may arise : a) the servomotor is designed to function at the pressure of the pipeline network. It shall therefore be capable of operating the valve down to the minimum possible operating pressure of the pipeline. b) the servomotor is designed to function at a constant pressure equal to or less than the minimum pressure of the network. In this case, the servomotor shall be provided with a pressure limiting device. In both cases as indicated it is recommended that a reservoir of driving fluid be provided. 3.6.1.14 Nitrogen or air operated servomotors If a pneumatic servomotor uses nitrogen or clean dry oil-free air as the driving fluid, it shall be designed in the same way as servomotors using oxygen. However, non-metallic materials for the sealing packings of the motor device (ram, piston and cylinder, etc) may be selected from outside of those stated in 2.1.2 and 2.1.4 and a label attached to the servomotor indicating NOT SUITABLE FOR USE WITH OXYGEN. 3.6.1.15 Electrically operated servomotors All electric servomotor parts shall comply with the requirements indicated in 3.6.0.8. 3.6.1.16 Hydraulically operated servomotors Hydraulic servomotors may be used with hydraulic incombustible fluids, providing suitable precautions are taken to prevent contact with the oxygen. 3.6.1.17 Emergency control Servomotors shall be provided with emergency control, enabling the valve to be closed in the event of failure of the operating power.
1982
Page 21 of 30
IGC
3.6.1.18 Fail safe device Automatic stop valves shall be provided with a fail safe device which operates in the event of the driving fluid or electric power being accidentally cut off. 3.6.1.19 Small manually operated valves A distinction shall be made between two groups of small valves for oxygen : a) Valves of a diameter 15 m or less normally used for pneumatic instrumentation. The closure device for these valves should be the metal to metal type. Valves of a diameter of between 20 and 40 mm inclusive generally used as shut-off, by-pass or purging valves in small and medium sized installations. The closure device should be of the metal to metal type, however a sealing device of non~metallic material recommended in 2.1.2 and 2.1.4 is permitted. All small manually operated valves should be constructed from copper alloy with the exception of their sealing equipment (O-rings, gland packing, etc) which shall be selected from the materials recommended in 2.1.2 and 2.1.4. b) 3.6.1.20 Small pneumatically operated valves Pneumatically operated valves of a diameter of between 15 and 40 mm inclusive * should be constructed from copper alloys similar to the small manually operated valves as indicated in Their closure device may include a non-metallic sealing device constructed from a material recommended in 2.1.2. If the pneumatic actuator uses oxygen it shall comply with the provision of 3.6.0 and should be able to withstand the design pressure of the valve. * For orifices of 15mm or under, electrically operated valves in accordance with 3.6.1.21 may be used. Pneumatically controlled valves may be used as : a) b) c) Venting valves; in this case the venting pipework should be made of copper or a copper alloy. Automatic by-pass valves on a shut-off or regulating component fitted on a main pipe. a shut-off valve
3.6.1.21 Electrically operated valves Electrically operated valves, with a diameter of 40 mm or under. Their sealing device may make use of the non-metallic materials recommended in 2.1.2 and 2.1.4. If these electrically operated valves are provided with a venting orifice, this shall be equipped with a copper pipe to ensure evacuation of the oxygen up to a point where it ceases to be dangerous. The valve part of all electrically operated valves should be copper alloys with the exception of the sealing devices which shall be selected from the materials recommended in 2.1.2 and 2.1.4. The electrical parts shall comply with 3.6.0.8. Materials other than those stated in 2.1.2 and 2.1.4 may be used to construct the electrical operated device. 3.6.1.22 Manual throttling valve These valves are used for pressuring and venting oxygen pipelines. All parts in contact with the gas shall be of copper alloy, and the closing device preferably free from non-metallic materials.
3.6.2
3.6.2.1
Automatic Control Valves

Definition An automatic control valve is a valve provided with a servomechanism which enables a given physical characteristic of a fluid to be regulated (or maintained constant) as required. In the case of oxygen distribution pipelines this physical characteristic is either the pressure or the rate of flow or both. Automatic control valves may also incorporate a limitation of flow function which comes into action only when the volumetric flow tends to exceed a predetermined maximum limit.
1982
Page 22 of 30
IGC
3.6.2.2
Compliance with this code Design and construction of automatic control valves shall conform to the general criteria of 3.6.0 and the requirements of 3.6.2. The Servomotors shall be designed to comply with the provisions of 3.6.1.12 to 3.6.1.16 inclusive concerning stop valves. Type of valve Automatic control valves may be of different types eg : single or double seated plug Butterfly Piston or cage Certain types of valves may also be equipped with a safety shutter which acts as an automatic shut-off element. This shut-off element shall always be fitted upstream of the valve port. Valves may include a noise reducing device providing it complies with recommendations of 3.5.3.
3.6.2.3
3.6.2.4
Materials of construction The body of the valve and its internal parts in contact with the gas should preferably be of copper base alloy. The gland packing and joints shall be leaktight and be made with authorised materials indicated in para 2.1.2 and 2.1.4. The valve stem shall operate without lubrication. Non leaktight valve installation Automatic control valves which are not leaktight when closed shall comply with the provision of 4.2.5.5. Standby manual operation If an automatic valve is provided with standby manual operation the latter shall meet the requirements of 3.6.1.8 and 3.6.1.9. Fail safe device It is recommended that servomotors shall be designed so as to cause the valve to close in the case of failure of its operating energy unless special circumstances dictate otherwise.
3.6.2.5
3.6.2.6
3.6.2.7
3.6.3
3.6.3.1
Non-Return Valves
Definition A non-return or check valve is a component which prevents reversal of the direction of flow of the fluid. Compliance with this code The design and construction of non-return valves shall conform to the general criteria of 3.6.0. Type of valves Non-return valves may be of different types e.g.: flap inclined flap ball single or double leaf. Leak-tightness Non-return valves shall be designed to ensure maximum leak-tightness in the closed position, i.e. when the upstream pressure is lower than the downstream pressure. Locking device Non-return valves may be provided with a device for locking their moving parts in the closed position. When steel valves larger than 40 mm dia used operation of this locking device shall be designed and made in such a manner as to allow its actuation from behind a protective screen.
3.6.3.2 3.6.3.3
3.6.3.4
3.6.3.5
1982
Page 23 of 30
IGC
3.6.3.6
Small non-return valves Small non-return valves with a diameter of 15mm or under shall be constructed in accordance with sections above. They shall be constructed entirely from copper alloy with the exception of their sealing devices which may be constructed from a material recommended in 2.1.2 and 2.1.4. The valves are generally used for instrument systems.
3.6.4
3.6.4.1
Pressure Reducing Valves

Definition A pressure reducing valve is a valve which enables the pressure downstream of it to be kept constant whatever the variation of flow and upstream pressure. Within the flow capacity limits of the valve and provided that the upstream pressure is greater than the downstream pressure. A pressure reducing valve differs from an automatic control valve in that it regulates the downstream pressure without the need for an auxiliary supply or control. Pressure reducing valves may be either gas or spring loaded. Compliance with this code The design and construction of pressure reducing valves shall be in accordance with the general criteria of 3.6.0. Loading gas The pressure reducing valve loading gas may be oxygen or clean dry oil free air or nitrogen Fail safe device All pressure reducing valves shall be designed in such a way that in case of rupture of its diaphragm or in the absence of the loading gas pressure it will automatically close. Balanced valves All pressure reducing valves with an orifice of 15 mm or more in diameter shall be of the balanced type so that control of the downstream pressure shall be maintained constant and not affected by the upstream pressure. Leak tightness The valve shall be designed to ensure maximum leak tightness in the closed position. Safety shut-off Reducing valves may be fitted with a safety device that will act as an automatic shut off. This closing device if fitted shall always be upstream of the reducing valve.
3.6.4.2
3.6.4.3 3.6.4.4
3.6.4.5
3.6.4.6 3.6.4.7
3.6.5
3.6.5.1
Filters
Function The function of filters is to arrest at selected points foreign bodies which are unavoidably conveyed by the gas flow in the oxygen pipelines (in spite of precautions taken). Dust and foreign bodies (whether combustible or not) may have either escaped initial cleaning or have been subsequently formed or introduced. Filtration enables: a) The prevention of erosion or even the deterioration of the moving parts and the seats of stop and regulation valves, as well as non-return valves. b) The prevention of wear of the orifice plates or venturis or the jamming (or heating by friction) of the moving parts of volumetric meters. c) The prevention of the incrustation of particles (whether heated or not) in components of fittings made of non-metallic materials. d) The prevention of dust (whether combustible or not) in suspension in a gaseous mass rapidly introduced into an enclosure of small volume from attaining a dangerous temperature (adiabatic compression). e) The elimination of the causes of spontaneous ignition of pipeline components or elements resulting either directly or indirectly from a flow of dust (see causes of accidents 1.4).
1982
Page 24 of 30
IGC
3.6.5.2
Recommended materials The filter bodies and elements shall be constructed solely from the materials authorised in 2.1 and conform with the general criteria stated in 3.6.0. Filter elements made from non-metallic materials If filter elements are fitted with non-metallic materials such as glass fibre these shall be thoroughly cleaned to remove manufacturing lubricants and assembled using copper wire to avoid accumulation of electrostatic charges. Filtration threshold The maximum filtration threshold will depend upon the extent of protection required. If filtration is necessary, the particle size threshold shall not exceed 200 x 10-3 mm (i.e. no particle over 200 micron in size shall be able to pass through the filter elements). Strength of filter elements The filter elements should preferably withstand without tearing or being ruptured, a pressure differential between the upstream and downstream of their filter surfaces equal to their maximum working pressure. Filters shall be provided with pressure differential measuring devices. The design and construction of filters shall be in accordance with the general criteria of 2.6.0.
3.6.5.3
3.6.5.4
3.6.5.5
3.6.5.6
Instrumentation filters Small filters used on oxygen services shall be constructed entirely of copper alloy with the exception of the sealing devices which may be selected from the materials recommended in 2.1.2 and 2.1.4. Oil type filters shall not be used. The filter elements should preferably withstand without tearing or being ruptured, a pressure differential between the upstream and downstream of their filter surfaces equal to the maximum working pressure.
3.6.6
3.6.6.1
Flowmeters and Meters

Function Flowmeters and meters are used to: measure the flow of gas (flowmeter) measure the quantity of gas (meter) or to perform both these functions simultaneously. The measurement can be used for: counting and verifying the quantities supplied monitoring a process ensuring operating safety (limitation of flow) Meters are generally made up of a flowmeter and an integrating system. Main types It is possible to distinguish three main types according to the measurement technique. a) Those that measure velocity : pressure differential, (orifice plate, venturi, nozzle, etc) vortex, impeller meters, etc. b) c) Those that measure volume : rotary piston (Roots), bellows, etc. Those that measure mass : hot wire meters, certain turbine meters, etc.
3.6.6.2
The following are also distinguished: a) Static meters, i.e. those that have no moving elements (pressure differential:- orifice plate, venturi, vortex hot wire, meters, etc). b) Dynamic meters, i.e. those having measuring elements in motion (rotary piston, bellows, impeller, turbine, etc., meters).
1982
Page 25 of 30
IGC
3.6.6.3
Selection Because of the features inherent in rotary machines (friction, the need for lubrication, sensitivity to excessive speeds, etc) preference shall be given to static meters wherever their measuring performance is able to satisfy users requirements. Volume correcting devices Flowmeters and meters may be provided with mechanical, pneumatic or electronic devices enabling conversion or correction of the gross flow into standard reference units. Conversions and corrections apply to: 3 factors : the pressure (P) the temperature (T) the compressibility coefficient (Z) or the specific mass which includes correction/conversion for P.T.Z.
3.6.6.4
3.6.6.5
Compliance with this code Flowmeters and their auxiliaries shall be designed and constructed in accordance with the criteria of 3.6.0 and the following special provisions. Lubrication Some dynamic meters require a reserve of lubricant. This shall be selected from among the products recommended in 2.2.1. If the lubricant is visible from outside, there shall be a label in a prominent position, fixed to the meter, specifying the grade of lubricant authorised. Renewal of the lubricant or the checking of it shall be by personnel authorised by the user. Bellows type As an exception for bellows type meters * with bellows requiring the use of a material not recommended in 2.1 these may be made up of diaphragms such as leather impregnated with a carbofluorinated oil providing they are compatible with oxygen. (see 2.2.1). Remote indication In the case of meters made of steel and having integral flow indicators or totalisers it is recommended that they be duplicated at a distance so that they can be read without approaching the meter. Auxiliaries Auxiliary apparatus for measuring temperature, pressure, specific mass, etc., shall comply with the provisions of 3.6.0 and 3.6.9.
3.6.6.6
3.6.6.7
3.6.6.8
3.6.6.9
3.6.6.10 Overspeed protection Some dynamic meters such as rotary piston meters are in danger of undergoing excessive deformation when their maximum permitted flow is exceeded. The friction caused by contact of the moving parts or entrained foreign particles may cause jamming, fracture and/or ignition. These meters shall be protected by a flow limiting device. This may be either incorporated in the pressure regulating assembly and be controlled by a flow/speed signal given by the meters or consist of an independent flow limiter component controlled by the velocity of the gas stream (see 3.6.9). Such a flow limiter shall be fitted at a distance of 3 to 5 diameters downstream of the meter and no other component shall be interposed between it and the meter.
Generally intended for measuring small flows (less than 100m3 /h gross).
1982
IGC
3.6.7
3.6.7.1
Safety Valves - Bursting Discs

Function The purpose of safety valves and bursting discs is to prevent a pipeline or pressure vessel, etc., from being subjected to a pressure higher than the maximum acceptable pressure. Compliance with this code Safety valves and Bursting Discs shall be designed in accordance with the general provisions of 3.6.0 and the following special requirements. Operating mode Safety valves and bursting discs shall be actuated directly by the fluid. Lifting pressure A safety valve shall open when the set pressure is reached (see 1.1.3.10) and shall be of adequate size in conformity with the provisions of 1.1.3.11. Bursting pressure A bursting disc shall burst in accordance with the provisions defined in 1.1.3.12. Multiple safety devices If more than one safety device is used, their combined total capacity shall be designed in accordance with the general provisions of 4.2.5.4 and the following special requirements. Duplication of safety devices When valves or bursting discs are duplicated, isolation devices shall be installed so that the system is always protected. Misadjustment Safety components shall be so designed as to prevent any possibility of inadvertent misadjustment. Safety valve materials With the exception of the spring, which may be of treated steel, the body and internal elements of safety valves should be made of copper alloy.
3.6.7.2
3.6.7.3 3.6.7.4
3.6.7.5 3.6.7.6
3.6.7.7
3.6.7.8 3.6.7.9
3.6.7.10 Disc material Bursting discs should be made of nickel. Their outer surface in contact with the atmosphere may be coated with a thin layer of PTFE or FEP in order to prevent deterioration by corrosion. 3.6.7.11 Leak tightness of s afety valves Safety valves shall be designed to ensure maximum leak-tightness in the closed position, preferably excluding seats of non-metallic materials, 3.6.7.12 Pilot devices Safety valves may comprise a pilot device designed to increase the accuracy of their setting. This device shall not affect any of the provisions listed above and its possible failure shall not prevent the valve from opening. 3.6.7.13 Vent pipes Safety components shall be provided with a vent pipe that ensures the removal of oxygen to a point where it ceases to be dangerous either to the plant or personnel. This vent pipe should preferably be of copper or copper alloy. 3.6.7.14 Periodic inspection The proper functioning of safety valves shall be periodically checked. 3.6.7.15 Periodic replacement of disc It is desirable that bursting discs be replaced by new ones periodically, depending on materials, conditions of use and experience.
1982
Page 27 of 30
IGC
3.6.7.16 Small safety valves Small safety valves with a diameter of 15 mm or under, shall be constructed in accordance with proceeding sections. They shall be constructed entirely from copper alloy with the exception of their sealing devices which may be constructed from a material authorised in 2.1.2 and 2.1.4. These valves are generally used for instrument systems.
3.6.8
3.6.8.1 3.6.8.2
Insulating Joints
Definition An insulating joint is essentially made up of two pipe elements separated by a dielectric material. Function The purpose of insulating joints is to provide permanent electrical discontinuity between the parts of the installation with cathodic protection and those without it. Ignition risks Because of this electrical discontinuity insulating joints carry potention danger of spontaneous ignition of the insulating material, caused by possible heating due to the joule effect. If, in the interior of a pipeline a continuous deposit of dust connects the two pipeline elements, and if the current intensity is sufficient, the dust may be brought to a temperature capable of initiating ignition of the insulating material. Compliance with this code Insulating joints shall be designed and made in accordance with the general criteria of para 3.6.0 and the following special provisions. An insulating joint should be made in a vertical pipe or inclined at 45 max. from vertical in order to avoid deposits through the effect of gravity.
3.6.8.3
3.6.8.4
3.6.8.5
Material in contact with oxygen The insulating material in contact with oxygen shall combine adequate mechanical with good dielectric qualities and comply with the provisions of 2.1.2. Material not in contact with oxygen Insulating materials not liable to be in contact with oxygen (insulants for nuts and bolts, external coating, etc) may be of materials other than those indicated in 2.1. Insulating capability An insulating joint shall be guaranteed to withstand a potential difference of 11000 volts (50 Hz) at a current intensity of less than 10 mA. Design and installation Insulating joints shall be made to reduce the possibility of the formation of a conducting bridge. For example, in the case of a flange type joint, the insulating part shall not be recessed.
3.6.8.6
3.6.8.7
3.6.8.8
1982
Page 28 of 30
IGC
3.6.9
3.6.9.1
Other Components
General criteria All the components mentioned in this section shall be designed and constructed in accordance with the general criteria of 3.6.0 and the following special provisions. The small items of equipment in accordance with 3.6.9.2 to 3.6.9.6 should be designed to function without lubrication in accordance with 3.6.0.13. If a lubricant is necessary to permit assembly operations or the functioning of the item of equipment, it shall be selected from the lubricants recommended in 2.2.1. Its use shall be kept strictly a minimum: The lubricant should be incorporated for life when the component is assembled and no trace shall be discernible from outside. Flow limiters The flow limiter is a component with a variable passageway under the direct action of the gas flow but independent of an auxiliary external device. If the design of the flow limiter makes use of a deformable diaphragm or bellows, these shall be of metal construction. Pressure sensors and indicators Pressure Sensors and indicators (manometers) may be divided into two groups: those in which the deformation of the sensitive element is measured mechanically (Bourdon tube or metal capsule) those in which this deformation is measured electrically (condenser, strain gauge, quartz, differential transformer). All parts in contact with oxygen should preferably be of copper alloy. All internal connections between the various components shall be made by brazing or welding. Dial gauges shall be provided at the rear with blow out plugs or bursting discs enabling the oxygen to escape in the event of fracture of the sensing element. Where there is no partition between the sensing element and the gauge window, safety glass shall be fitted. Sensors and indicators with electrical devices shall be constructed in accordance with 3.6.0.8. If sensors use hydraulic fluid this fluid shall be taken from materials recommended in 2.2.1 and shall not be in direct contact with oxygen. All pressure sensors and indicators shall bear the clearly visible inscription OXYGEN, no oil or grease.
3.6.9.2
3.6.9.3
3.6.9.4
Pneumatic control device The pneumatic control devices can be operated using oxygen providing that materials are compatible with oxygen.(see 2.1.1, 2.1.2 and 2.1.4) and that vented gas can be conveyed to a safe place. Temperature sensors and indicators Where temperature measuring devices such as resistance probes, thermocouples or mercury bulbs are used, they should be welded or brazed into the pipeline in a pocket of stainless steel or copper alloy to prevent corrosion. Sensors with electrical devices shall be constructed in accordance with 3.6.0.8. Temperature indicators which require direct reading at the place of measurement should not be used with oxygen.
3.6.9.5
1982
Page 29 of 30
IGC
3.6.9.6
Miscellaneous items of equipment All miscellaneous items of equipment not stated in 3.6.9 and which may be used with oxygen in regulating and control devices shall be constructed from copper alloy and their non-metallic components constructed solely from the materials recommended in 2.1.2. They shall also comply with the general provisions of 3.6.0 and the special requirements of 3.6.9.1. In particular, items which include electrical components shall conform to the recommendations in 3.6.0.8. There are no special requirements regarding the selection of supply current and voltage for electrical equipment.
1982
Page 30 of 30
IGC
The Transportation and Distribution of Oxygen by Pipeline Part 4 : Equipment
IGC 13/82/E
1982
Page 1 of 65
IGC
PART 4 : INSTALLATIONS................................................................................................................................6 4.1 THE DESIGN AND TESTING OF INSTALLATIONS .........................................................................................6 4.1.1 General ..............................................................................................................................................6
4.1.1.1 4.1.1.2 4.1.1.3 4.1.1.4 4.1.1.5 4.1.1.6 Design criteria ..............................................................................................................................................6 Design procedure for the pipeline.................................................................................................................6 Other design criteria .....................................................................................................................................6 Choice of design and test methods ...............................................................................................................6 Effects on the environment...........................................................................................................................6 Physical constants - oxygen..........................................................................................................................6
4.1.2
4.1.2.1 4.1.2.2 4.1.2.3
Velocity ..............................................................................................................................................7
General .........................................................................................................................................................7 Calculation of velocity..................................................................................................................................8 Maximum velocity in pipelines ..................................................................................................................10
4.1.2.3.1 4.1.2.3.2 4.1.2.3.3 4.1.2.3.4

4.1.2.4 4.1.2.5
Carbon steel pipelines ......................................................................................................... 10 Copper and copper alloy pipelines ...................................................................................... 10 Stainless steel pipelines ....................................................................................................... 10 Other materials .................................................................................................................... 10
Components................................................................................................................................................10 Other factors that limit velocity..................................................................................................................10
4.1.3 4.1.4
4.1.4.1 4.1.4.2 4.1.4.3
Pressure Losses ...............................................................................................................................11 Mechanical Strength and Wall Thickness of the Pipes ....................................................................12
Characteristics of carbon and low alloy steels ............................................................................................12 Calculation formulae ..................................................................................................................................12 Permissible stresses ....................................................................................................................................13
4.1.4.3.1 4.1.4.3.2 4.1.4.3.3

4.1.4.4
Steel pipes for transportation pipelines ............................................................................... 13 Steel pipes for stations......................................................................................................... 13 Copper, copper alloy and stainless steel pipes..................................................................... 13
Choice of Pipes...........................................................................................................................................13
4.1.5 4.1.6 4.1.7 4.1.8

4.1.8.1 4.1.8.2
Design of Components.....................................................................................................................13 Noise ................................................................................................................................................14 Cold .................................................................................................................................................14 Design of Installations.....................................................................................................................14

General dimensions ....................................................................................................................................14 Design of stations .......................................................................................................................................15
4.1.9
4.1.9.1 4.1.9.2
Testing - Method and Test Levels ....................................................................................................15

Choice of method .......................................................................................................................................15 Tests for transportation pipes .....................................................................................................................15
4.1.9.2.1 4.1.9.2.2
4.1.9.3
Specially ordered pipes (according to 4.1.4.3.1) ................................................................. 15 Ppipes that are not specially ordered ................................................................................... 15 First possibility overall test at 1.5 times design pressure .................................................... 15 Second possibility individual testing of pipes at 1.5 times maximum design pressure ....... 16
Tests for station pipework ..........................................................................................................................15
4.1.9.3.1 4.1.9.3.2
4.1.9.4
Prefabricated elements and components.....................................................................................................16
4.2 DESIGN AND CONSTRUCTION OF STATIONS.............................................................................................16 4.2.1 Location of Stations and Access ......................................................................................................16
4.2.1.1 4.2.1.2 4.2.1.3 Choice of location ......................................................................................................................................16 Access to and exits from stations................................................................................................................16 Roads and general utilities..........................................................................................................................17
4.2.2
4.2.2.1 4.2.2.2 4.2.2.3 4.2.2.4 4.2.2.5 4.2.2.6 4.2.2.7
Protection by Walls or Screens........................................................................................................17

Stations requiring protection ......................................................................................................................17 Size of stations ...........................................................................................................................................17 Spacing requirements .................................................................................................................................17 Function of protection screens....................................................................................................................17 Arrangement of screens..............................................................................................................................17 Design of screens........................................................................................................................................18 Choice of screens and structural arrangements...........................................................................................21
4.2.3
4.2.3.1
Buildings for Stations ......................................................................................................................21

Closed buildings .........................................................................................................................................21
4.2.3.1.1 4.2.3.1.2
1982
Walls and partitions............................................................................................................. 21 Structural materials.............................................................................................................. 21

IGC
4.2.3.1.3 4.2.3.1.4 4.2.3.1.5 4.2.3.1.6 4.2.3.1.7

4.2.3.2
Roofs of buildings ............................................................................................................... 22 Natural ventilation............................................................................................................... 22 Forced ventilation................................................................................................................ 22 Exits - lighting..................................................................................................................... 22 Venting at atmosphere......................................................................................................... 22
Outdoor construction ...............................................................................................................................22
4.2.3.2.1 Protection walls ................................................................................................................... 22 4.2.3.2.2 Roofing................................................................................................................................ 22 4.2.3.2.3 Shelters ................................................................................................................................ 23 4.2.3.2.4 Ducts.................................................................................................................................... 23 4.2.4 Stresses due to the Ground and to Temperature Changes...............................................................23
4.2.4.1 4.2.4.2 Forces due to the ground ............................................................................................................................23 Forces due to temperature change ..............................................................................................................23
4.2.5
4.2.5.1
Design Rules for Stations.................................................................................................................23

Valves.........................................................................................................................................................23
4.2.5.1.1 4.2.5.1.2 4.2.5.1.3 4.2.5.1.4 4.2.5.1.5

4.2.5.2 4.2.5.3 4.2.5.4
Choice of valve operation.................................................................................................... 23 Manual operation................................................................................................................. 23 By-pass valves..................................................................................................................... 24 Automatic operation by servomotor .................................................................................... 24 Small manual or motorised valves....................................................................................... 25
Vents and pressure tappings on a pipeline..................................................................................................25 Temperature tappings .................................................................................................................................25 Safety device ..............................................................................................................................................25
4.2.5.4.1 4.2.5.4.2 4.2.5.4.3

4.2.5.5 4.2.5.6 4.2.5.7 4.2.5.8 4.2.5.9 4.2.5.10 4.2.5.11 4.2.5.12 4.2.5.13 4.2.5.14 4.2.5.15 4.2.5.16 4.2.5.17 4.2.5.18
Safety valves ....................................................................................................................... 26 Bursting discs ...................................................................................................................... 26 General requirements .......................................................................................................... 26
Pressure or flow regulating components.....................................................................................................27 Metering components .................................................................................................................................27 Other components.......................................................................................................................................27 Layout of station pipework.........................................................................................................................27 Auxiliary pipework.....................................................................................................................................27 Pipework and cables in ducts ..................................................................................................................27 Wall, partition and screen crossings........................................................................................................27 Electrical and pneumatic instrumentation ...............................................................................................28 Electrical installation ..............................................................................................................................28 Electrical continuity/earthing..................................................................................................................28 Cathodic protection.................................................................................................................................28 Soundproofing ........................................................................................................................................29 Supports and fixings ...............................................................................................................................30 Firebreak sections ...................................................................................................................................30 Materials.....................................................................................................................................................30 Design, construction...................................................................................................................................30 Continuity of internal diameters .................................................................................................................31 Headers.......................................................................................................................................................33 Tees and branches ......................................................................................................................................33 Vent, pressure and temperature tappings ....................................................................................................33 Dead ends ...................................................................................................................................................33 Cleaning and cleanliness ............................................................................................................................33
4.2.6
4.2.6.1 4.2.6.2 4.2.6.3 4.2.6.4 4.2.6.5 4.2.6.6 4.2.6.7 4.2.6.8
Prefabricated Pipework...................................................................................................................30
4.2.7
4.2.7.1 4.2.7.2 4.2.7.3 4.2.7.4 4.2.7.5 4.2.7.6 4.2.7.7
Construction of Stations ..................................................................................................................34

Start of the work .........................................................................................................................................34 Cleanliness during construction..................................................................................................................34 Fitting of pipeline components and elements .............................................................................................34 Welding on site...........................................................................................................................................34 Gaskets, nuts and bolts ...............................................................................................................................34 Auxiliary pipework.....................................................................................................................................34 Painting, cleaning of the premises ..............................................................................................................35
4.2.8
4.2.8.1 4.2.8.2 4.2.8.3 4.2.8.4 4.2.8.5
1982
Final Inspection...............................................................................................................................35
General .......................................................................................................................................................35 Verification of conformity..........................................................................................................................35 Verification of cleanliness ..........................................................................................................................35 Verification of leak-tightness .....................................................................................................................35 Verification of operation ............................................................................................................................35
IGC
4.2.8.6
Protection of the station..............................................................................................................................35
4.3 DESIGN & CONSTRUCTION OF PIPELINES ................................................................................................36 4.3.0 GENERAL........................................................................................................................................36 4.3.1 Study of the route.............................................................................................................................36 4.3.2 Drafting the Plans ...........................................................................................................................36 4.3.3 Regulations for Conduct of the Work...............................................................................................36 4.3.4. Supply of Pipes ................................................................................................................................36
4.3.4.1 4.3.4.2 4.3.4.3 4.3.4.4 Steel pipes ..................................................................................................................................................36 Internal treatment .......................................................................................................................................36 Sealing of pipe ends ...................................................................................................................................36 External protection .....................................................................................................................................37
4.3.5
Pipeline Construction ......................................................................................................................37

Staking out, marking and route preparation................................................................................................37 Excavation of the trench .............................................................................................................................37 Handling of the pipes..................................................................................................................................37 Making of bends.........................................................................................................................................37 Tappings and shapes...................................................................................................................................37 Preparation for welding ..............................................................................................................................37 Welds and approvals...................................................................................................................................37 Recording of welds.....................................................................................................................................37 Inspections of welds ...................................................................................................................................38 Junctions .................................................................................................................................................38 Test of welded sections...........................................................................................................................38 Sections waiting to be laid ......................................................................................................................38 On-site coating........................................................................................................................................38 Inspection of the coating.........................................................................................................................39 Laying in the trench ................................................................................................................................39 Backfilling ..............................................................................................................................................39 Warning of underground pipeline ...........................................................................................................39 Underground crossing of roads ...............................................................................................................39 Underground crossing of railroads..........................................................................................................39 Waterway crossings ................................................................................................................................39 Overhead crossings .................................................................................................................................39 Crossing or running alongside underground services..............................................................................39 Crossing drains .......................................................................................................................................40 Proximity of overhead high tension cables .............................................................................................40 Construction in the proximity of high tension cables..............................................................................41 Above-ground sections ...........................................................................................................................42
4.3.5.1 4.3.5.2 4.3.5.3 4.3.5.4 4.3.5.5 4.3.5.6 4.3.5.7 4.3.5.8 4.3.5.9 4.3.5.10 4.3.5.11 4.3.5.12 4.3.5.13 4.3.5.14 4.3.5.15 4.3.5.16 4.3.5.17 4.3.5.18 4.3.5.19 4.3.5.20 4.3.5.21 4.3.5.22 4.3.5.23 4.3.5.24 4.3.5.25 4.3.5.26
4.3.6 4.3.7
4.3.7.1 4.3.7.2 4.3.7.3
Pipeline Cleaning ............................................................................................................................42 Tests .................................................................................................................................................42

Strength test................................................................................................................................................42 Leak tightness test ......................................................................................................................................42 Typical test procedures...............................................................................................................................42
4.3.8 Cathodic Protection.........................................................................................................................43 4.3.9 Restoration of the Terrain ...............................................................................................................43 4.3.10 Pipeline Identification .....................................................................................................................43 4.3.11 Pre-Commissioning Tests ................................................................................................................43 4.3.12 As Built Drawings............................................................................................................................43 4.3.13 Supervision of the Work Site............................................................................................................43 4.4 SUPPLY STATIONS ...................................................................................................................................61 4.4.1 General ............................................................................................................................................61 4.4.2 Function...........................................................................................................................................61 4.4.3 Construction ....................................................................................................................................61 4.4.4 Special Considerations ....................................................................................................................61 4.5 VALVE STATIONS ....................................................................................................................................61 4.5.1 General ............................................................................................................................................61 4.5.2 Function...........................................................................................................................................61 4.5.3 Construction ....................................................................................................................................61 4.5.4 Special Considerations ....................................................................................................................62 4.6 DISTRIBUTION STATIONS ........................................................................................................................62 4.6.1 General ............................................................................................................................................62 4.6.2 Function...........................................................................................................................................63
1982 Reproduced in IMSS with permission Page 4 of 65
IGC
4.6.3 Construction ....................................................................................................................................63 4.6.4 Special Considerations ....................................................................................................................63 4.6.5 Protection of Customers Network....................................................................................................63 4.7 RECOMPRESSION STATIONS ....................................................................................................................63 4.8 PRESSURE REDUCTION STATIONS ...........................................................................................................63 4.9 STORAGE VESSELS (BUFFERS) ................................................................................................................64 4.9.1 General ............................................................................................................................................64 4.9.2 Construction of Buffers....................................................................................................................64 4.9.3 Design..............................................................................................................................................64
4.9.3.1 4.9.3.2 4.9.3.3 4.9.3.4 4.9.3.5 4.9.3.6 4.9.3.7 4.9.3.8 Regulations and design...............................................................................................................................64 Design pressure ..........................................................................................................................................64 Piping connections .....................................................................................................................................64 Flange connections .....................................................................................................................................64 Stop valves and vent valves........................................................................................................................64 Safety valves...............................................................................................................................................64 Manholes ....................................................................................................................................................64 Ladders and attachments ............................................................................................................................64
4.9.4
4.9.4.1 4.9.4.2 4.9.4.3
Inspection and Cleaning ..................................................................................................................65

Inspection and tests ....................................................................................................................................65 Cleaning .....................................................................................................................................................65 External finish ............................................................................................................................................65
4.9.5
4.9.5.1 4.9.5.2
Installation.......................................................................................................................................65
Foundations and supports ...........................................................................................................................65 Valves and controls ....................................................................................................................................65
1982
Page 5 of 65
IGC
PART 4 : INSTALLATIONS
4.1
4.1.1
4.1.1.1
The Design and Testing of Installations

General
Design criteria The three basic criteria that determine the design of pipes and components are: Gas velocity for safety reasons Pressure losses so as to obtain flow conditions compatible with operating requirements. Mechanical strength (pressure, temperature and stress). Where modifications are made to an existing network, the new conditions of pressure, flowrate and velocity throughout the system shall he verified. Design procedure for the pipeline For each section of pipeline, the flow rate and required pressure being known the usual sequence of calculations will be as follows: a. Determination of the diameter so as to obtain an acceptable pressure drop. b. Verification of the velocity and possible adjustment of the diameter so as to observe velocity limits. c. Calculation of the minimum wall thickness. (Resistance to pressure). Other design criteria Other criteria shall also be taken into consideration. These are especially : Pressure effects due to changes of direction Static loads of equipment Forces due to the wind Stresses due to variations in temperature (expansion, contraction) Stresses due to the ground conditions Effects of vibration Effect on existing supporting structures and installations Effects of corrosion Effect of temperature on permissible stress values Possible legal classification of pipeline location Choice of design and test methods In most countries there are regulations, codes and standards for the design for mechanical strength of installations or at least of components. The indications given here may, however, be used for the calculation of strength and testing in countries that have no specific regulations but they shall not be substituted for those of countries that have them. Effects on the environment Considerations regarding noise and cold shall also be taken into account (See 4.1.6 and 4.1.7). Physical constants - oxygen Table XII gives some values of physical constants for Oxygen necessary for certain calculations.
4.1.1.2
4.1.1.3
4.1.1.4
4.1.1.5 4.1.1.6
1982
Page 6 of 65
IGC
TABLE XII Physical constants at 15C (288K) Pressure gauge bar 0 1 5 10 15 20 30 40 50 60 70 Specific heat CP = kJ / kg. K 0.9187 0.9200 0.9271 0.9359 0.9451 0.9547 0.9735 0.9932 1.0129 1.0327 1.0539 Temperature 0 C 15C Thermal conductivity W / cm K 0.2535x10-3 0.2543 0.2577 0.2630 0.2667 0.2705 0.2790 0.2876 0.2962 0.3049 0.3137 1013mb abs 1,4290 1,3543 Compressibility factor Z = PV/RT 0.9994 0.9985 0.9960 0.9921 0.9885 0.9849 0.9780 0.9714 0.9649 0.9590 0.9537 1 bar abs 1,403 1,3366 Dynamic viscosity Poisseuille (PI) 2.003x10-5 2.005 2.014 2.022 2.032 2.042 2.062 2.074 2.114 2.142 2.172
Mass Specified in Grams per Litre
4.1.2
4.1.2.1
Velocity
General Velocity is not dangerous in itself. It becomes a risk factor mainly in the presence of dust and other foreign bodies which conveyed at high speed, may be raised to a high temperature by friction or impact.
1982
Page 7 of 65
IGC
4.1.2.2
Calculation of velocity Velocity means the gas velocity in a given cross section calculated under the conditions of pressure and temperature and flow. Actual flow rate by volume V = Cross sectional area 4Q PD2 106 3600 Q D
2
P0TZ PT0Z0 TZ
1.313
V Q D P T Z P0 T0 Z0
velocity of gas in m/s flow in m3/h under reference conditions P0, T0 ID of pipe in mm absolute gas pressure in bar gas temperature in K coefficient of compressibility under flow conditions P and T 1.013 bar absolute reference pressure 273.15 K reference temperature 0.9994 coefficient of compressibility under reference conditions P0, T0 = 4 106 3600 P0 T0Z0
1.313
For approximate calculation, neglecting the factors T and Z the formula becomes : Q PD2
358
V Q P D 358
velocity in m/s flow in M3/h abs pressure in bar diameter 4 106 = 3600
= = = =
1.013
The diagram (Fig 24) was made with the aid of this last approximate formula. It allows a quick reference and relatively accurate vertification of the velocity in relation to QP and D.
1982
Page 8 of 65
IGC
1982
Page 9 of 65
IGC
4.1.2.3
Maximum velocity in pipelines The following recommended limits for the velocity of flow are based on the test - and operating results by the oxygen European Manufacturers and Distributors and on the experience of other competent authorities and organisations. These values vary for a given pressure condition and are dependent upon the standard of pipeline cleanliness and assurance that the standard of cleanliness can be maintained under all operating conditions of the system. Carbon steel pipelines For correctly designed and maintained installations the velocities shown by curve A of the graph of Fig 25 are recommended. If there is any doubt regarding the cleanliness of the installation or where design and operating experience is limited, velocities defined by curve B Fig 25 are recommended.
4.1.2.3.1
4.1.2.3.2
Copper and copper alloy pipelines In pipelines of copper and copper alloy it is not necessary to limit velocities. Where high velocities are unavoidable, the use of these materials is preferred.
4.1.2.3.3
Stainless steel pipelines Stainless steel has the advantage that once cleaned, the internal cleanliness is easily maintained. Velocities used for stainless steel vary according to developed working practices. Where these working practices have not been developed, it is recommended that permissible velocities shown by Graph A Fig 25 be used.
4.1.2.3.4
Other materials For all other metallic materials, the velocities permitted shall be the same as those allowed for steel.
4.1.2.4
Components For components of reduced cross section, the smallest cross section shall not be less than 1/3 the cross section of the pipeline. In regulator components the possibility of sonic velocities may be accepted. In every case the components and installations shall comply with the criteria defined in this Code. Other factors that limit velocity The maximum velocities permitted are rarely used in practice, because other factors intervene to keep the velocities at relatively low levels. Two such factors are : Pressure losses, which increase rapidly with the velocity Vibrations, which may be prohibitive due to the behaviour of components the excessive noise created
4.1.2.5
1982
Page 10 of 65
IGC
Fig. 25 MAXIMUM FLOW VELOCITIES OF OXYGEN IN CARBON STEEL PIPELINES
For use of this diagram see 4.1.2.2 and 4.1.2.3 A Maximum permissible velocities B Maximum velocities if doubt exists regarding cleanliness of the installation
4.1.3
Pressure Losses
Loss of pressure is a loss of mechanical energy of the fluid due to friction between the fluid and the walls of the pipeline on the one hand and between the various particles of the fluid on the other. This lost energy is representative of the energy required for transportation. A distinction is made between : Regular pressure losses: those caused by flow through a straight cylindrical pipe of constant cross section. Particular pressure losses : those caused by peculiarities of the pipe (sudden changes of cross section or direct, components inserted in the pipeline, etc). Reference should be made to text books for the evaluation of pressure losses for pipe components. Some of these formulae are used for the design of slide rules, charts or computer programmes that can be used for calculating pressure losses. For application of the formulae the main characteristics of oxygen are given in 4.1.1.6.
1982
Page 11 of 65
IGC
4.1.4
Mechanical Strength and Wall Thickness of the Pipes

In chapter 3.2.1 manufacturing requirements have been defined. Where regulations and standards are not available for carbon or low alloy steels, the basic characteristics are defined in 4.1.4.1 corresponding calculation formulae shown in 4.1.4.2 permissible stresses in 4.1.4.3 and testing in 4.1.9.
4.1.4.1
Characteristics of carbon and low alloy steels The following values are recommended : Rm max 580 Nmm2 Re max / Rm max A min Rm max x A min KCV 0.80 18% 10.500 2.8 daJ/cm2
0.43 wt% C + Mn/6 METAL - shall be homogeness, weldable and killed - shall present good resistance to ageing - shall be suitable for cold bending on site In the formulae: Rm Re Max Min A KCV C + Mn/6 C Mn S = = = = = = = = = = U.T.S. Newton/mm2 Yield, Newton/mm2 for 0.2% elongation maximum tolerance - Highest value minimum tolerance - lowest value Elongation % for length 5.65 x S Impact test value daJ/cm2 of Charpy notch specimen at -20C Weldability coefficient Carbon % Manganese % Cross section area of test piece in mm.
The above characteristics concern steels which have a guaranteed UTS of up to 520 Newton/mm2 For higher UTS steel a more detailed study is required to suit existing regulations. 4.1.4.2 Calculation formulae The minimum wall thickness can be calculated from the following formulae: PD 100 + td e= 20fz + 2P 100 te where: f = the allowable stress for the pipe material in N/mm2 p = the design pressure in bar D = the outside diameter in mm td = the maximum plus tolerance for the diameter in % e = the minimum wall thickness in mm te = the maximum minus tolerance on wall thickness in % z = welding coefficient = 1 for seamless pipe or specially inspected welded pipe For a specific pipe transposition of this formulae makes it possible to calculate the pressure and stress. 100 + td P (D Ze) f= 20eZ 100 te P= 20efZ D Ze 100 te 100 + td
1982
Page 12 of 65
IGC
4.1.4.3 4.1.4.3.1
Permissible stresses The maximum permissible stresses recommended below take the various customary safety factors into consideration. Steel pipes for transportation pipelines As a general rule, the pipes used to construct an Oxygen transportation pipeline can be ordered specially and tested in accordance with 4.1.9.2.1. For these pipes the following stress values are permitted : a The maximum stress permitted shall be less than the smallest of the values below when buried 0.73 Re (yield) 0.55 Rm (UTS) when above ground 0.73 Re (yield) 0.44 Rm (UTS) Re is the conventional limit of elasticity (yield) with a guaranteed minimum of 0.2% Rm is the guaranteed minimum breaking stress (UTS) b The maximum works test stress shall be less than or equal to 10/11 of the limit of elasticity. If the pipes cannot be purchased as a special order to above conditions, they shall comply with 4.1.4.3.2.
4.1.4.3.2
Steel pipes for stations For the station pipes the maximum stress in service shall be less than the lowest of the following values: f 0.625 - Re f 0.33 - Rm The maximum stress under test pressure shall not exceed 0.95 Re.
4.1.4.3.3
Copper, copper alloy and stainless steel pipes The formula in 4.1.4.2 may also be used for these pipes. The stress rates permitted for working or testing shall be those laid down by the manufacturers or the competent organisations.
4.1.4.4
Choice of Pipes It will generally be an advantage to choose a pipe of standard size and verify that the dimensions satisfy the results of calculation. It may also be necessary to take pipe of greater thickness than that calculated to ensure the pipes resistance to crushing or to provide satisfactory conditions for welding.
4.1.5
Design of Components
Most countries have their own regulations or codes for the calculation of pressure vessels. The calculation and tests necessary to establish strength functioning and capacity of components is the responsibility of the manufacturer based on agreed regulations, codes or standards where applicable. It does not lie within the scope of this Code to define the conditions for the calculation of pressure vessels or components. In the case of imports it is advisable to check whether the design of the components of the country of origin comply with the requirements of the importing country. The choice of components shall be made from equipment which complies with the safety specifications mentioned in part three of this Code.
1982
Page 13 of 65
IGC
4.1.6
Noise
Noise caused by the rates of flow and gas expansion in installations is not generally of a sufficiently high level to justify special attenuation measures. For some installations, however, steps to limit noise may be necessary. Possible sources of noise are : the gas flow expansion of the gas mechanical vibration moving parts Noise may be reduced by careful design of pipework and selection of items of equipment. It is also possible to reduce noise levels by means of insulation of pipework, locating equipment inside buildings, insulating buildings, etc. In the course of operations large scale venting of short duration to atmosphere on isolated sites, may be necessary which exceeds the noise levels usually permitted. It is recommended the immediate neighbourhood and the services concerned (police, fire brigade, municipal authorities, railways, etc) should be advised.
4.1.7
Cold
The expansion of oxygen generates cold. Within the usual range of pressure and temperature there is cooling of the gas of the order of 0.28C per bar pressure drop for free expansion. The approximate temperature differential is given by the formula: T = 0.28 (PA-PB) Where 273 TA
T is the temperature drop K PA is the pressure before expansion PB is the pressure after expansion TA is the absolute temperature of the gas before expansion K It is thus possible to obtain a temperature lower than 0C. As the gas is dry, cooling does not affect the functioning of equipment. External condensation and possible icing has only a minor effect upon the behaviour and appearance of equipment but under exceptional conditions, freezing may prevent the operation of certain components. The effect of cold upon the environment is exceptional, however, if the pipework enters the ground on leaving the stations, cooling of the ground may then entail frost damage to roads or the blocking of neighbouring water pipes by freezing. Precautions should be taken to avoid these consequences.
4.1.8
Design of Installations
The main elements of design of installations are the strength of the pipeline and components, verification of velocity and pressure losses. A number of other factors, including stress analysis are dealt with in 4.2 for the installations as whole and 4.3 for the transmission pipeline. Certain aspects of distribution supply and valve stations are dealt with in the following paragraphs.
4.1.8.1
General dimensions The choice of components will depend upon flow rate, pressure and pressure drop. The type of equipment and especially flow meters influence the length and configuration of pipe required. The diameter of pipework and dimension of components will affect the configuration of the installation.
1982
Page 14 of 65
IGC
4.1.8.2
Design of stations The design and construction of the stations shall take into account all civil and mechanical engineering requirements. The civil engineering part of the work comprises the foundations, the walls or screens, the supports and bedding of pipes and components. The design of screens (when required) is dealt with in 4.2.2.5. The problems of stresses due to the ground and to variations in the outside temperature are dealt with in 4.2.4, see also 4.4 to 4.9.
4.1.9
4.1.9.1
Testing - Method and Test Levels

Choice of method Oxygen is a clean, dry gas and should be supplied with these qualities. Internal pollution of pipelines also acts against safety. If it desirable not to contaminate the pipelines by hydraulic testing which leaves behind moisture and dust consisting of rust. It is therefore advisable to proceed to drying and cleaning after hydraulic testing. These operations are difficult on pipelines of great length. Hydraulic testing should be avoided if possible, following the recommendations of 4.3.7.1 Tests for transportation pipes Specially ordered pipes (according to 4.1.4.3.1) The following 3 tests are mandatory : 1. Hydraulic strength test at the factory, individually for each pipe at a pressure equal to at least 1.21 times the design pressure. The maximum stress under test shall observe the limit laid down in 4.1.4.3.1. 2. Strength test on the site of the completed system at a pressure equal to at least 1.1 times the design pressure. This test may be pneumatic if the conditions of 4.3.7.1 are observed. 3. Pneumatic leak-tightness_test on the site of the completed system at a pressure at least equal to the design pressure.
4.1.9.2 4.1.9.2.1
4.1.9.2.2
Ppipes that are not specially ordered The following 3 tests are mandatory: 1. Individual hydraulic strength test for each pipe at a pressure equal to 1.5 times the design pressure. The maximum stress under test shall observe the limit laid down in 4.1.4.3.2. 2. Strength test on the site of the completed system at a pressure of at least 1.1 times the design pressure. This test may be pneumatic if the conditions of 4.3.7.1 are observed. 3. Pneumatic leak-tightness test on site at a pressure at least equal to the design pressure.
4.1.9.3 4.1.9.3.1
Tests for station pipework One or other of the methods below is current practice in a number of countries. First possibility overall test at 1.5 times design pressure The following 2 tests are necessary: 1. Hydraulic strength test of assemblies or sub-assemblies at a pressure of at least 1.5 times the design pressure. This test is generally preceded by non-destructive testing of the welds by selection (connections of pipes and coupling elements: tees, elbows etc). The maximum stress under test shall observe the limit laid down in 4.1.4.3.2. 2. Pneumatic leak-tightness tests at a pressure at least equal to the design pressure. NOTE: After testing, the closing welds shall be subjected to 100% to non-destructive testing.
1982
Page 15 of 65
IGC
4.1.9.3.2
Second possibility individual testing of pipes at 1.5 times maximum design pressure The following 3 tests are necessary: 1. Hydraulic strength test of the pipes at a pressure of at least 1.5 times the design pressure, on each pipe individually before it is put into service. The maximum stress under pressure shall observe the limits laid down in 4.1.4.3.2. 2. Pneumatic strength test of the assembly at a pressure of 1.1 times the design pressure after compulsory 100% non-destructive testing of all welded joints. 3. Pneumatic leak-tightness test at a pressure not exceeding the design pressure. NOTE: After testing, the closing welds shall be subjected to 100% non-destructive testing.
4.1.9.4
Prefabricated elements and components These parts shall be subjected to a hydraulic strength test at 1.5 times the design pressure and possibly to a leak-tightness test after assembly. The maximum stress under test shall not exceed 0.95 Re. NOTE 1. The regulations of some countries require the hydraulic strength test to be repeated every 10 years. In some cases these regulations allow exemption from this rule for certain elements if the original test pressure is twice the service pressure. Calculation of the element shall therefore be carried out in such a way that the permissible stresses are not exceeded in the course of testing. NOTE 2. The regulations of some countries provide for the omission of calculation and testing of components by substituting destructive tests of sample models.
4.2
Design and Construction of Stations

This section deals basically with provisions for the design and construction of the stations detailed in 4.4 to 4.9.
4.2.1
4.2.1.1
Location of Stations and Access

Choice of location In order to prevent errors of operation the location of oxygen stations shall. be chosen so as to observe a degree of isolation from installations for the distribution of flammable gases, air, water, etc. The station should be surrounded by a fence. It is necessary to avoid the immediate proximity of: tanks or storage receptacles of flammable products main public roads It is necessary to avoid locations where stations could be subject to: oil dripping from installations situated above them (machinery, handling equipment) Projected cinders or incandescent bodies Projected materials of any kind Access to and exits from stations Access to the stations and components shall be easy to facilitate quick evacuation of personnel in the event of an accident. Door locks shall be of the panic type, easily opened from inside or incapable of being closed when personnel are inside. Exits shall open into free spaces clear of obstacles. Locations chosen shall also enable necessary handling operations to be carried out under favourable conditions.
4.2.1.2
1982
Page 16 of 65
IGC
4.2.1.3
Roads and general utilities The station shall be served by an access road suitable for motor vehicles. For supply stations of large capacity or distribution stations with a large output, the following should be provided. A source of electric power for the supply to equipment. Powerful and robust lighting equipment sufficient to illuminate work area and exits. Electric cables supplying this equipment shall be adequately protected. Suitable power socket for maintenance operation.
4.2.2
4.2.2.1
Protection by Walls or Screens

Stations requiring protection Where installation of large stations comprising components for which experience or knowledge is insufficient to guarantee resistance to ignition under all possible conditions of operation, walls or screens are recommended if adequate spacing cannot be obtained. Size of stations Large stations shall be considered as those for which the highest value of the pressure multiplied by the square of the diameter for any pipe or components in the station exceeds the following limit. PD2 > 3000 Where P is the gauge pressure in bar, and D is the nom dia in cm. Spacing requirements In the case of installations according to 4.2.2.1 protection by walls or screens is necessary if the distances shown in fig 26 cannot be observed. Function of protection screens The purpose of screens is to contain the effects of incident and ensure the protection of: operators maintenance personnel the surrounding area components from each other Screens and protection walls shall be made such that maintenance personnel and operators can work safely. Dividing screens are used mainly in installations comprising parallel systems. They enable work to be carried out on one system while adjacent systems remain in service. Arrangement of screens Various arrangements may be contemplated, according to the type of station. A number of typical examples are represented in fig 27. The exists shall be located in such a manner to stop flying objects and facilitate exit of the personnel. See fig 28 for typical chicane type exits. The distance between screens shall be kept to a minimum compatible with the size of equipment, assembly work, operation and maintenance.
4.2.2.2
4.2.2.3
4.2.2.4
4.2.2.5
1982
Page 17 of 65
IGC
4.2.2.6
Design of screens Screens shall be vertical and their height shall ensure effective protection, it should generally not be less than 2 metres. Protection by screen is open to the sky (outdoor installation). Reinforced concrete walls constitute efficient screens. The strength of screens of lighter design shall be ensured by means of a supporting framework. The loads to be taken into account for the calculation of screens are : a) The conventional Loads due to wind The weight of the screen itself Loads due to supports b) Accidental Loads In addition to conventional loads the screen shall be capable of withstanding an exceptional load defined as follows: A force uniformly distributed over the entire height of the screen and limited locally to a width of 3 metres, over the length of the screen. The load per square metre will depend upon the size of the station, it is expressed as follows as a function of category: Category I ii PD Size
2
Load 120 kgf /m2 80 kgf /m2
8000
3000 PD2 8000
1982
Page 18 of 65
IGC
1982
Page 19 of 65
IGC
Fig. 27 TYPE OF PROTECTION WALLS OR SCREENS
1982
Page 20 of 65
IGC
4.2.2.7
Choice of screens and structural arrangements The choice will depend upon requirements and upon experience acquired. Screens shall be capable of withstanding the loads described in 4.2.2.6 and the materials used shall have good resistance to impact and fire. There are various possibilities: Walls of reinforced concrete Walls of prefabricated blocks Walls of reinforced concrete panels Asbestos cement panels Composite (sandwich) panels Attention is drawn to the need for careful study of anchorages and supporting for resistance to blast. Steel panels provide good resistance to blast and impact, but on the other hand they burn easily in an oxygen atmosphere. Composite panels shall comprise combinations of plates or layers of metal and non-combustible materials (asbestos, cement, silicate etc).
4.2.3
Buildings for Stations

So-called outdoor installations are recommended because they offer a higher degree of safety. Closed premises of small size are more liable to be subject to an oxygen-enriched atmosphere.
4.2.3.1 4.2.3.1.1
Closed buildings Walls and partitions The walls and partitions of a closed building shall be constructed based on the recommendations of 4.2.2. The surrounding walls, not exposed to possible damage, may be constructed of ordinary structural materials (bricks, prefabricated blocks, etc). The height of buildings shall be sufficient to permit easy manipulation of the pipeline components and elements.
4.2.3.1.2
Structural materials The buildings shall be constructed entirely of non-flammable materials, including the floor, doors, framework, etc.
1982
Page 21 of 65
IGC
4.2.3.1.3
Roofs of buildings Roofs shall be capable of stopping projected incandescent materials (reinforced concrete, metal structures with sheets of asbestos cement, etc). Where there is forced ventilation the building shall be provided with blow out flaps so that perforation of the pipeline will not give rise to any dangerous internal excess pressure.
4.2.3.1.4
Natural ventilation A free space of at least 0.5 m high shall be arranged over the entire periphery (except the posts) between the walls and the roof for removing smoke and gases and to prevent pressurisation of the building in the event of extensive leakage due to fracture. The open area thus created shall be at least 100 times the cross section area of the biggest pipe element in the building. In order to assist ventilation, whether natural or forced, grilled openings with a total area of (open area / 20) shall be provided at the lowest part of the walls.
4.2.3.1.5
Forced ventilation If natural ventilation cannot be considered (excessive dustiness of the atmosphere) forced filtered inlet ventilation shall be provided, and one or more extraction fairs fitted high in the walls to draw the air from the building and exhaust it to the outside. The total delivery rate of these ventilators shall be sufficient to renew the atmosphere of the building at least 3 to 4 times per hour. It is not necessary for these ventilators to operate continuously. They may be linked to: an abnormal increase (greater than 22%) of the oxygen concentration in the building. the opening of one of the doors to ensure the renewal of the air before entering the premises. Exits - lighting Closed buildings shall have a sufficient number of exits. Their location shall be studied in relation to the position of the components requiring attention (filters, meters, valves, etc). These exits shall be brightly lit, even during the day when work is being done, so as to be seen through smoke in the event of a fire. This lighting shall be switched on automatically when a door is opened and shall only be extinguishable by means of a manual switch inside the building in the immediate vicinity of the exits. Doors of the building shall be of the emergency exit (panic' type) opening outwards simply by being pushed (see 4.2.1.3). Electrical equipment for lighting shall be of standard design and comply with recommendations in 4.2.5.13.
4.2.3.1.6
4.2.3.1.7
Venting at atmosphere Venting lines for valves, vents, pneumatic instrumentation using oxygen as the driving fluid, etc., shall lead into a manifold and be vented outside of buildings by means of copper or copper alloy pipelines. (See 4.2.5.4.3).
4.2.3.2 4.2.3.2.1
Outdoor construction In 4.2.2 the provision of protection by a wall or screen is recommended for some large installations. Protection walls In order to ensure good rigidly and stability of the structure and to prevent blow out of walls in the event of an incident the following are recommended: walls integral with the floor and foundation partitions integral with the floor and foundations acting as supports to the main walls. linking by means of lintels In order to prevent disintegration and projection through walls, the spacing of reinforcements should be limited (25cm may be used as a guide).
4.2.3.2.2
Roofing In outdoor installations, control instruments may require protection against inclement weather. Where the instrument room forms part of the station structure, the roof shall be made of reinforced concrete. (Fig 29)
1982
Page 22 of 65
IGC
4.2.3.2.3
Shelters It may be necessary to provide a shelter above certain delicate components to protect them from the rain or to facilitate maintenance. Fragile sheets such as those of fibrocement shall be avoided because of the danger they present in the event of fragmentation. Use may be made of flexible light materials or solidly fixed safety glass panels.
4.2.3.2.4
Ducts If ducts are required for instrument lines (pipes and cables), they shall have a slope of at least 1% in order to permit drainage. They shall be connected to an outfall. Ducts shall be covered by reinforced concrete slabs or chequered steel plate
4.2.4
Stresses due to the Ground and to Temperature Changes

Every line should be the subject of calculation which takes into account expansions and settlement differentials. The design shall take account of permissible stressing of components. The use of expansion devices should be considered see 3.5.2.
4.2.4.1
Forces due to the ground Forces due to ground changes shall be taken into account when designing the station. These may arise from: settling of the ground undermining of the ground modification of the characteristics of the ground effect of change of water table. Forces due to temperature change Forces may result from the differential effect of ambient temperature on systems made up of two parts, one of which is above and the other below ground.
4.2.4.2
4.2.5
Design Rules for Stations

The number of components should be kept to a minimum compatible with requirements since they may be the most likely cause of incidents. All components shall comply with Part 3 of this code. Instructions for the installation of components shall be observed (i.e. handling, supporting, direction of flow, etc).
4.2.5.1 4.2.5.1.1
Valves Choice of valve operation Shut-off valves may be manually or automatically operated according to the design of stations and opertional requirements.
4.2.5.1.2
Manual operation If a manually operated valve is installed behind a protective screen or wall (see 4.2.2) its operating handwheel shall be in front of the wall. Use may be made of: an extended operating rod, or an angled lever device. If a device without an effect angle is used, a stop shall be provided integral with the extension of the operating rod so that in case of accident the rod or handwheel cannot strike the operator. Fig 29 shows some examples of manual operation of a valve. SAFETY ARRANGEMENTS OF VALVE OPERATING SPINDLES The object of these arrangements is to prevent the spindle or the handwheel from striking the operator in the event of explosion or projection.
1982
Page 23 of 65
IGC
4.2.5.1.3
By-pass valves It is recommended that stop valves of inside diameter 150mm or more should not be opened until the pressures upstream and downstream have been balanced (see 3.6.1.6). Stop valves may be supplemented by a by-pass valve in accordance with 3.6.1.19. In horizontal pipelines upstream and downstream connections for the by-pass valves shall be installed above the horizontal centre line of the pipe. (Fig 30A).
If electrically or pneumatically operated by-pass valves according to 3.6.1.20 are used, the inside diameter should be equal to or less than : one-fifth the inside diameter D of the main pipeline, if the distance from the stop valve to the next following shut-off component is equal to or greater than 100 D. one-tenth of the inside diameter D of the main pipeline in other cases. On valve stations up to 400mm diameter, the diameter of the by-pass valves should not be greater than 100mm and should be sized according to volume of the downstream system. In by-pass valves high velocities prevail during balancing of the pressures. Use shall, therefore, be made only of valves made of copper alloy. If the main shut-off valve is behind a protective screen, the by-pass valve should also be behind the screen if its inside diameter is equal to or greater than 15mm. If this valve is manually operated it shall be provided with an extension to allow its handwheel to be in front of the wall or screen. 4.2.5.1.4 Automatic operation by servomotor It shall not be possible for a shut-off valve equipped with motorised operation to be opened before the pressures upstream and downstream of it have been balanced. For this purpose, the operating circuit shall be designed so that the by-pass valve opens first. When the pressures upstream and downstream are practically equal (ratio between the two equal to or less than 1.1) the main valve may be opened. In the case of a signal to close, the main valve and its by-pass shall close simultaneously.
1982
Page 24 of 65
IGC
If a pneumatically operated valve is operated by means of oxygen taken from the network, a reserve capacity of driving fluid shall be provided, separated from the network by non-return valve. This reserve capacity shall be sufficient and suited to the system. If the pilot operation device makes use of electrical energy, it should preferably be designed so that the shut-off valve closes if the current is cut off. 4.2.5.1.5 Small manual or motorised valves If the installation includes protective screens or walls (see 4.2.2) all valves greater than 15mm shall be installed behind the screens. 4.2.5.2 Vents and pressure tappings on a pipeline Vent valves and pressure tappings shall be installed on the top part of a horizontal pipe (see fig 30).
The vent valve of a filter shall be installed downstream of the filter (on the filtered gas side) according to fig 31.
4.2.5.3
Temperature tappings Temperature tappings shall be effected by means of a pocket The pocket shall be of stainless steel or copper alloy. They shall not penetrate to a depth of more than 0.5 D into the pipeline (D being the inside diameter of the pipeline). If the pocket is fitted to a horizontal pipeline it shall be fixed to the top part of the pipe in the same way as pressure tappings (see 4.2.5.2). If the pocket is liquid-filled, this shall be non-flammable and shall not freeze at operating temperature (-30 to + 80C). The sensitive elements (thermocouples, resistance probes, etc) shall be fitted inside the pockets and not directly into the gas stream. Safety device The requirement for safety devices such as safety valves or bursting discs in sections liable to exceed the design pressure is generally prescribed by national regulations. The design and construction of these safety components shall comply with the recommendations in section 3.6.7. Safety valves have the advantage of closing when the pressure has fallen to the permitted level. Bursting discs have the disadvantage of completely venting the parts of the network protected to atmosphere as soon as they burst. Bursting discs shall be used with working pressures sufficiently below their calibration pressure so as to avoid premature bursting due to metal fatigue.
4.2.5.4
1982
Page 25 of 65
IGC
4.2.5.4.1
Safety valves Oxygen installations if necessary shall have two or more valves according to the following criteria: a) one or more main valve(s) capable of venting the entire flow of the pressure reducing valve in the event of failure, and limiting pressure within defined limits. No shut off component shall separate the main valve or valves from the line protected except as stated in 3.6.7.7. b) A secondary valve designed to evacuate any possible leak flow from the pressure reducing valve. For example the set pressure of the valves may be chosen according to the criteria indicated in the following table. Set pressure (valve begins to open) If secondary valve If secondary valve with without isolating valve isolating valve Secondary 1P 0.95P Main 1.03 to 1.05P 1P P may be any value lower than the maximum allowable operating pressure Valve The secondary valve may be isolated from the pipeline by means of a shut-off valve, to facilitate maintenance. Safety valves, whether main or secondary, should be fitted between the downstream side of the pressure reducing valve and the upstream side of the shut~off valve, as shown in fig 32.
4.2.5.4.2
Bursting discs As an alternative to one or more main safety valves, a bursting disc or discs may be used. Bursting disc installations should preferably include a secondary relief valve designed to evacuate any possible leak flow from the pressure reducing valve. The secondary valve may be isolated from the pipeline by means of a shut-off valve to facilitate maintenance. The maximum bursting pressure of the discs see 11.3.12 shall comply with the demands of the system and shall be defined as follows: If bursting discs only are fitted their bursting pressure shall be equal to or lower than the maximum allowable working pressure. If a secondary valve is fitted which opens at the design pressure the bursting pressure of the main disc can be defined for 1.1 designed pressure. No isolating valve shall be fitted between the bursting disc and the line except as defined in 3.6.7.7. General requirements If the station comprises several lines having pressure reduction equipment, safety devices shall be fitted behind the protective walls. Safety devices shall be provided with a vent pipe which ensures the evacuation of oxygen to a point where it does not present a hazard to personnel or the installation. Because of the high velocities prevailing in vent pipes, these should preferably be made of copper or copper alloy, they shall be as straight as possible and firmly secured to withstand reaction forces.
4.2.5.4.3
1982
Page 26 of 65
IGC
4.2.5.5
Pressure or flow regulating components If the station is provided with pressure or flow regulating components these shall be fitted downstream of a filter. If the pressure regulating component is of a type that is not leaktight in the closed position (e.g. double seated clack valves) it may be preceded by an automatic leaktight shut-off valve operated by the pressure downstream of the reducing valve. If the main components are installed behind protective walls or screens, regulation auxiliaries that necessitate the approach of an operator shall be installed away from the reducing valve (e.g. in a control room). A flow limiting component may be fitted either upstream or downstream of a meter except in the case of a volumetric meter with moving parts and if the component is independent of the meter. In this case, it shall be fitted downstream of the meter in order to avoid excessive revolutions of the meter. Metering components Metering components may be fitted downstream or upstream of flow or pressure components except in the case of volumetric meters mentioned in the last paragraph of 4.2.5.5. Metering components with moving parts shall be preceded by efficient filtration to the meter manufacturers specification. If the main components are installed behind protective walls or screens, metering auxiliaries that necessitate the approach of an operator shall be installed away from the meter or be duplicated so as to make remote control and readings possible (e.g. in a control room). Other components Other components (filters, insulating flanges, etc) which form part of the installation shall follow the basic recommendations indicated in this section. Layout of station pipework The pipework of a station shall be if possible above ground level, straight, horizontal and changes of direction avoided. If changes of cross section are required, reducers according to section 3.3.2 shall be used. Buried sections shall not include components or mechanical joints. Auxiliary pipework Pipes for by-passing shut-off valves, venting pipes and auxiliary pipes for instrumentation should preferably be of copper or copper alloy in accordance with 3.2.0.3 and 3.2.2. Auxiliary pipes leading to instruments or control equipment should not be laid at ground level. They should be grouped together in ducts or on racks as well as electric cables for instrumentation. Buried section shall not include components or mechanical joints.
4.2.5.6
4.2.5.7
4.2.5.8
4.2.5.9
4.2.5.10 Pipework and cables in ducts It is advisable to avoid the installation of main pipelines in ducts. It is desirable that pipes and cables do not rest directly on the bottom of the duct but on a raised rack. Instrument pipes or cables where laid in ducts. Lines containing oxygen located in ducts shall not include mechanical joints or components. Pipelines conveying flammable fluids or electric power cables ( 380v) shall not be installed in the same ducts containing oxygen pipelines 4.2.5.11 Wall, partition and screen crossings Holes or slots in walls or screens for pipework and valve stem extension shall be constructed over-size to allow for assembly. After assembly the openings to be finally sealed shall be finished with concrete, after the pipe has been covered with a strip (rubber, plastic, etc) at least 5mm thick to provide the necessary flexibility for the pipe. The passageways for extension stems shall be lined with PVC sheaths before sealing off with concrete. In some cases, use may be made of sealing plates but concrete is recommended. See Fig 33.
1982
Page 27 of 65
IGC
4.2.5.12 Electrical and pneumatic instrumentation If instrumentation is grouped together in an enclosed building, the latter must have sufficient ventilation to prevent the accumulation of air enriched with oxygen in the event of possible leakage from the oxygen instrumentation circuits. The vents shall comply with 4.2.3.1.7. The supply voltage for electrical instrumentation should be normally less than 250V-AC or 50V-DC. Pneumatic instrumentation shall be equipped with an isolating valve according to section 3.6.1.19 to permit maintenance of the apparatus. 4.2.5.13 Electrical installation Electrical installation of a station may be effected with standard equipment provided the equipment is installed in an adequately ventilated building. Equipment installed in the open shall be weatherproof. Explosion-proof equipment, where oxygen may come into contact with electrical parts does not improve the level of safety. Electric cables shall be of adequate section for the current carried. 4.2.5.14 Electrical continuity/earthing Care shall be taken to ensure that the whole of the station pipework installation is permanently at the same electric potential. For this purpose all flange couplings, excluding insulating joints shall be electrically bonded for example by means of copper braid under heads of bolts of at least 20mm section. The contact surfaces shall be clean and free from oxidation or paint. See 3.6.0.7. If the flanges are fitted with electrically conductive gaskets it is unnecessary to bridge them with braiding. Various earthing arrangements are possible, a typical arrangement is shown in fig 34. If the station is under cathodic protection see 4.2.5.15. 4.2.5.15 Cathodic protection Two cases may arise: The station is not under cathodic protection: This is the most frequent case of distribution stations and the installation shall be earthed. The station is under cathodic protection This may be the case for valve stations for which the installation shall be insulated electrically from earth and installations designed accordingly. In particular : wall penetrations Instrumentation couplings supports valve stem extension Valve stem extension shall have an insulating joint for the protection of operators and this joint shall be capable of transmitting the operating torque to the componment.
1982
Page 28 of 65
IGC
4.2.5.16 Soundproofing The soundproofing of pipework installed in the open air may be effected by means of acoustic insulation covering according to section 3.5.3.2. Where insulation covers flanged connections, it shall be made removable so that any leakage may be detected. If acoustically insulated parts have pressure or temperature tappings, these shall be made in such a way that the connections are outside the insulating coating.
1982
Page 29 of 65
IGC
4.2.5.17 Supports and fixings Heavy components such as filters, shall be fixed on rigid supports of reinforced concrete or metal structure solidly anchored to the ground. Heavy components subject to vibration, such as rotary piston volumetric meters, etc., must be fixed to footings of reinforced concrete. Components such as valves, diaphragm flowmeters, flow limiters, etc., may be held by means of fixed or adjustable height supports (see fig 35 for typical example of adjustable support). Where possible, station equipment and supports should be mounted on one common base. Small installations running along a wall may be fixed to the latter by means of metal angle brackets. Supports for pipework and components shall be designed to allow acceptable movements only.
4.2.5.18 Firebreak sections In the past, copper pipe or stainless steel sections known as firebreaks were sometimes installed in the hope of limiting the propagation of combustion of a steel pipeline. Practical experience and research during more than 20 years of operation of oxygen pipelines has now shown that in the event of ignition, the fire very quickly stops of its own accord, thereby confirming the theoretical explanation referred to in 1.3.1. For this reason, firebreaks are not recommended.
4.2.6
4.2.6.1
Prefabricated Pipework
Materials Pipework connecting the various components of a station shall be made of materials recommended in section 2.1.1 from pipes according to 3.2 and shapes according to 3.3 and 3.4. Use may be made of pipes and fittings made of carbon steel and assembled by welding. In some cases where high velocities may prevail, e.g. valve station by-passes, prefabricated copper or copper alloy elements may be used. Design, construction Prefabricated pipework shall be designed and constructed in accordance with the standards and regulations in force in the country where they are to be used. Welds shall comply with the recommendations of 4.3.5.7.
4.2.6.2
1982
Page 30 of 65
IGC
4.2.6.3
Continuity of internal diameters Care must be taken to ensure that for any given nominal diameter the pipes, flanges and fittings making up a prefabricated element are of the same schedule i.e. of the same inside diameter (fig 36). If for any reason it is necessary to use pipes and flanges of different schedules, a chamfer shall be made on the element of smaller diameter as shown in (fig 36). Tees reductions and other alterations of section shall avoid protusions or changes of profile. See Fig 37 and 3.3.2.
1982
Page 31 of 65
IGC
1982
Page 32 of 65
IGC
4.2.6.4
Headers In the case of installations comprising lines in parallel headers shall preferably be made according to the diagram in fig 39.
4.2.6.5 4.2.6.6
Tees and branches Couplings of two pipe elements by Tee shall comply with the recommendations of section 3.3.4. Vent, pressure and temperature tappings Tappings for vent valves or pressure or temperature gauges welded to prefabricated elements shall comply with the recommendations of 4.2.5.2 and 4.2.5.3. Dead ends Elements comprising dead ends shall be avoided, especially downstream of expansion components fig 40.
4.2.6.7
4.2.6.8
Cleaning and cleanliness After assembly, prefabricated pipeline elements shall be cleaned and treated according to the recommendations of 2.3.6.
1982
Page 33 of 65
IGC
4.2.7
4.2.7.1
Construction of Stations
Start of the work Assembly of components and pipework should not begin until the main civil engineering work (foundations, walls, paving, etc) is completed. Cleanliness during construction Personnel entrusted with the assembly and erection of the installations shall wear reasonably clean working clothes that are not stained with oil or grease and keep their hands washed clean of all oil, grease, etc. for tools and handling see 6.1.4. Fitting of pipeline components and elements Protective plugs or seals of components or pipework shall not be removed until the last moment before fitting. Before their assembly, it shall be ensured by visual inspection that they are clean and do not contain any trace of oil or grease or any foreign body. Care shall also be taken to remove any dehydration sachets that may be inside components or pipework and to avoid introduction of impurities or foreign bodies into items of equipment during assembly. When work stops (at night, for holidays, etc) all openings shall be effectively sealed by plastic caps or other clean, safe and watertight means. In the event of lengthy interruption of work (more than a week) or at the end of assembly if taking into service is not immediate, the installation shall be filled with dry oil free nitrogen. The whole of the pipework and components shall be aligned in relation to the points of reference. During the assembly and erection of pipework and components care shall be taken to ensure that flanges are concentric, parallel/perpendicular to the axis of the pipeline. Correction for bad alignment by excessive tightening of the bolts or by using mechanical means such as levers, winches, clamps, jacks, etc., is not permitted. When the bolts of a flange joint are loosened, the faces of the two flanges shall remain parallel and concentric without moving appreciably away from each other. Welding on site If welds have to be made on site, the components and pipework shall be carefully cleaned and degreased if necessary, according to the recommendations of 4.2.6 before they are placed in their final positions. (See 2.3.6.2). Gaskets, nuts and bolts Gaskets shall be clean and comply with the recommendation of 2.1.4. Nuts and bolts of flanges shall comply with the recommendations of 3.4.1.8 and be degreased before assembly by means of a solvent recommended in 2.2.2. Excessive tightening of nuts and bolts shall be avoided and the relevant instructions be observed. In the absence of specified tightening torques, the rules of the art will be observed as a function of the nature and size of the flanges and bolts, of the working pressure anticipated and of the nature of the gasket. The threaded ends of bolts may be covered by plastic or rubber caps in order to prevent the screw threads from being coated with paint or from corroding. Auxiliary pipework Small auxiliary pipework made on site shall, before being connected to their respective components and instruments, be carefully cleaned and degreased according to the recommendations of 2.3.2, and 2.3.2.6. Couplings shall comply with the recommendations of 3.4.2. Pipes for venting to atmosphere shall be horizontal and bevelled at 45 to prevent entry of rainwater, etc.
4.2.7.2
4.2.7.3
4.2.7.4
4.2.7.5
4.2.7.6
1982
Page 34 of 65
IGC
4.2.7.7
Painting, cleaning of the premises When the final inspection has been satisfactorily carried out according to the recommendations of 4.2.8, the following finishing work shall be undertaken : if the installation includes protective walls, the openings in them for pipelines and manual valve extension stems shall be closed in accordance with the recommendations of 4.2.5.11. any grouting of components or their supports to their respective foundations shall be effected. carbon steel components and pipework shall be given a protective coating of anticorrosive paint. Care shall be taken to see that no damage is done to components or pipelines in the course of this work. care shall be taken to avoid oxygen enrichment while paint is drying. at the end of the work the station shall be cleaned and any elements not necessary for its operation, such as wood blocks, tools, rags, papers, pots of paint and solvents, handling equipment, etc., be removed.
4.2.8
4.2.8.1
Final Inspection
General Final inspection shall take place after complete assembly of the installation to verify compliance with 4.2.7 and testing in accordance with 4.1.9. Verification of conformity The conformity of the installation with the drawings and specifications shall be verified. Check that there are no abnormal stresses by removal of bolts from flanged joints, one at a time to verify that the faces of the two flanges remain parallel and concentric, and do not come apart. Verification of cleanliness The cleanliness of the installation shall be verified by disconnecting and inspecting selected pipework elements and components of the station in accordance with the recommendations of 2.3.8.2 and 2.3.8.3. They shall not contain contaminants or foreign bodies as indicated in 2.3.0.2. If necessary, the disconnected elements shall be cleaned according to the recommendations of 2.3.6.2 and verification shall be extended to the remainder of the installation. Verification of leak-tightness Following removal of components and elements for inspecting and their subsequent replacement. The leak-tightness of the installation shall be verified by means of the materials and methods recommended in 2.2.7 using clean dry oil free air or nitrogen at a pressure of 1 to 2 bar. Any leakage detected shall be marked and repaired when the installation has been depressurised. The operation shall be repeated until leak-tightness is obtained. After satisfactory results of leak-tightness at 1 to 2 bar, the pressure shall be increased in steps to the maximum working pressure and leak-tightness checks repeated. Verification of operation Using nitrogen or oil-free air, the setting and operation of automatic elements shall be simulated and verified. In particular: the opening and closing of automatically operated valves the setting and operation of electric, pneumatic and electro-pneumatic regulators and metering devices. the operation of safety valves, by increasing the pressure of the test medium up to their set value. the internal leak-tightness of shut-off valves by depressurising one or other of the pipe sections of the station. Protection of the station After the inspection and testing of the station, painting and cleaning of the premises shall be effected according to the recommendations of 4.2.7.7. The station and associated pneumatic circuits shall be filled and maintained under an atmosphere of nitrogen until they are put into oxygen service.
4.2.8.2
4.2.8.3
4.2.8.4
4.2.8.5
4.2.8.6
1982
Page 35 of 65
IGC
4.3
4.3.0
Design & Construction of Pipelines

GENERAL
Pipelines may be buried or above ground. For medium or long distances, the pipelines will normally be buried. The construction of oxygen pipelines shall be effected in accordance with the same general techniques as those for the laying of pipelines for gases under pressure, with, in addition, a certain number of precautions which will be enlarged upon in following paragraphs. These are mainly precautions to be taken in order to ensure the CLEANLINESS REQUIRED FOR OXYGEN INSTALLATIONS. Apart from these precautions, the pipelines shall be made in accordance with : the statutory regulations in force in the country, national or international standards, the professional rules concerning proper execution of the work.
4.3.1
Study of the route

Study of the route of an oxygen pipeline shall take the following into consideration, on both privately and publicly owned property: The geographical situation of the points to be supplied. The terrain: hills, wooded areas, mining subsidence areas, built-up areas, motorways, railways, rivers, etc. The nature of the subsoil: water table, rock, marshland, etc. The existing installations: pipelines, pylons for high tension electricity lines, etc. The views of owners (private or authorities) utilising or controlling the land traversed. The view of owners, users or controllers of buried or above-ground structures crossed by or running alongside the pipeline.
4.3.2
Drafting the Plans

When the survey of the route is complete, together with calculations as necessary, the following plans and documents shall be made. A layout of the pipeline on a map, with marking of roads, railways, rivers, etc. Survey plans for rural and urban areas or factories to the required scale. Plans for crossings or longitudinal usage of roads, railways, rivers and canals. Plans and descriptions of special areas such as marshlands, drained areas, undulations and other obstacles. A list of usages of publicly and privately owned territory, indicating the manner of laying and protection.
4.3.3
Regulations for Conduct of the Work

The owner of the pipeline to be installed shall ensure that the agreement with the contractor contains reference to the safety, legal and other requirements on both privately and publicly owned property associated with the construction of pipelines.
4.3.4.
4.3.4.1
Supply of Pipes
Steel pipes All pipes shall be hydraulically tested. See 4.1.9, 3.2 and 4.1 deals with the problems of selection, manufacture and calculation of pipes. Internal treatment The completed oxygen pipeline shall have been degreased internally and be free from scale and rust and any coating or lining. Internal cleaning of the pipe shall be carried out in accordance with 4.3.6. Sealing of pipe ends When the pipes have been cleaned on the manufacturers premises they shall at once be sealed at both ends to prevent contamination and corrosion see 2.3.9.4. A check shall be made at the time of delivery and at the various handling operations to see that the seals are properly in place. When the seals are removed a check shall be made to ensure that nothing (plugs, dehydrating sachet) is left inside the pipes.
4.3.4.2
4.3.4.3
1982
Page 36 of 65
IGC
4.3.4.4
External protection The external protection of the pipes may be carried out either on the manufacturers premises or on site. See 4.3.5.13 or 3.2.1.8.
4.3.5
4.3.5.1 4.3.5.2
Pipeline Construction
The following operations will be carried out. Staking out, marking and route preparation Excavation of the trench It is recommended that the trench be excavated to provide a minimum cover for the pipeline of 0.75 m or to suit local conditions. See Fig 41. The bottom of the excavation shall be free from all materials which could damage the coating of the pipeline. If necessary, a layer of sand shall be spread over the bottom of the trench. Handling of the pipes When handling, care shall be taken to ensure that the external coating of the pipe is not damaged also that end seals remain in position. Making of bends Bends shall be formed using a purpose designed machine. Bends having corrugations, sharp changes in wall contour or unacceptable wall thinning shall not he permitted. If pigs are to be used for pipe cleaning, bends shall be sized to suit. The bends will be made with pipe of the same quality as those used for construction of the pipeline. If a method is used which requires filling the pipe with sand, it will be necessary to ensure internal cleanliness of the tube after bending. If coated pipes are bent care shall be taken not to damage the coating. When bends are made on longitudinally welded pipes the line of the weld shall be located on the neutral axis of the bend or at 45 to the neutral axis. Tappings and shapes These shall be made as shown in 3.3 and 4.2.6. In particular, the bottom line of different section shall be in the same horizontal plane to prevent low points which form dust traps. Preparation for welding The end seals shall only be removed from each pipe just prior to positioning of pipe for welding. It is necessary at this time to check that no foreign body remains inside the pipe. If use is made of internal clamps these shall not be lubricated, and if they are pneumatic the medium used shall be dry oil free air or nitrogen. Welds and approvals Assembly of the pipes shall be effected by welding. The welding process and the choice of electrodes or filler metal shall be selected to suit the steel of the pipes. The welders shall pass recognised qualification tests. Welds shall have full penetration but protrusions into the pipe bore shall be strictly limited. The root run may be by argon arc (T.I.G.) welding. The advantage of this process is that less internal splattering occurs and a smoother surface behind the welding line is ensured. Where internal cleaning is impracticable the tig process may be recommended. On some sites good results can be difficult to achieve due to adverse weather conditions or site peculiarities. In the event of the use of welded pipes, the seam welds on adjoining pipes should be offset from each other by at least 10 cm. Recording of welds Each weld shall be given a number, this number shall be shown on reference plan of the pipes or on a welding log-book. In these documents, opposite each weld number, shall be shown the name of the welder or his reference number together with information relative to the assessment of the weld.
4.3.5.3
4.3.5.4
4.3.5.5
4.3.5.6
4.3.5.7
4.3.5.8
1982
Page 37 of 65
IGC
4.3.5.9
Inspections of welds In addition to visual inspection, welds shall be subjected to a non-destructive inspection by X-rays or gamma rays. The following minimum requirement for non-destructive testing is recommended based on the proven acceptable repeatability of individual welders performance. 100% until 10 consecutive acceptable welds are obtained 75% until 10 consecutive acceptable welds are obtained 50% until 10 consecutive acceptable welds are obtained 30% until 10 consecutive acceptable welds are obtained One weld chosen at random from each group of 10 welds. In the event of in unacceptable defect in the course of the 75%, 50%, 30%, and 10% inspections, one weld upstream and one downstream of the defective one shall be inspected. If these inspections detect an unacceptable weld, the strictness of inspection shall revert to 100% before the law of diminuation indicated above is re-applied. If use is made of an internal inspection device the carriage for the transfer of the device shall not be lubricated and if it is pneumatic the medium used shall be dry oil free air or nitrogen. Closing weld and welds made on pipeline elements underneath high-ways, motorways, railways, rivers or in the vicinity of houses, shall be 100% inspected. The decisions of the inspection organisation with regard to the acceptance or rejection of a weld shall be final.
4.3.5.10 Junctions No violent thermal or mechanical means for facilitating positioning of elements shall be tolerated, which would introduce stresses to or damage the installation. Adequate protection shall be provided to prevent ingress of water into the enlarged section of trench where welding is to be carried out. 4.3.5.11 Test of welded sections A pneumatic test of the welded sections may be made before the welds are coated, with verification of the leak-tightness of the welds with soapy water. 4.3.5.12 Sections waiting to be laid When sections have been assembled but not connected: in a trench or not in a trench preinstalled sections road, railway, etc, crossings these sections shall be carefully plugged. Similarly, when work stops, the open ends of the pipeline shall be sealed. 4.3.5.13 On-site coating If the pipes have been ordered bare on the outside from the manufacturer, coating will be done on-site. It may be effected: by means of glass cloth coated with coal tar by means of glass cloth coated with petroleum bitumen by means of glass cloth coated with adequate plastic tape The coating shall adhere perfectly to the pipe. The coating shall be doubled in areas where the corrosive nature of the soil makes this necessary. It shall also be doubled: at crossings of cables and pipes at the base of high tension electricity pylons on pipe sections in mud on pipe sections inside metal sheathing inside concrete channels at points where the pipe emerges from the ground. The pipeline may be protected by a covering of suitable materials.
1982 Reproduced in IMSS with permission Page 38 of 65
IGC
4.3.5.14 Inspection of the coating Immediately before laying in the trench, the insulation of the coating shall be verified in dry weather by the passage of an insulation tester at 10 000V. Any defect shall be marked and repaired immediately. 4.3.5.15 Laying in the trench The bottom of the trench shall be free from all objects or pebbles capable of damaging the coating. If necessary for example in stony ground, the bottom of the trench shall be provided with a layer of sand. The pipeline shall then be laid in the trench by using methods and equipment which ensures that the coating is not damaged. When ballasting or anchoring the pipeline in areas where movement of soil can take place, every precaution shall be taken to ensure that the protective coating is not damaged. 4.3.5.16 Backfilling Backfilling up to a level of 20 cm above the top of the pipeline shall be effected with care, using selected uncontaminated materials free from any large or sharp objects which could damage the protective coating. 4.3.5.17 Warning of underground pipeline A warning plastic grid or tape shall be placed above the buried pipeline in the course of backfilling at all points where this is considered to be necessary. 4.3.5.18 Underground crossing of roads These crossings may be made by drilling, thrust boring or open trench according to the size of the road to be crossed and the nature of the sub-soil and the requirements of the appropriate authorities. Sheaths may be constructed of asbestos cement, concrete or steel. Care shall be taken in the design and construction of the crossing to ensure the effectiveness and reliability of Cathodic Protection of the pipeline, also the ability to withstand without deformation the forces due to filling materials and traffic loads. See drgs 42, 43, 44 and 45 for typical examples. 4.3.5.19 Underground crossing of railroads The provisions described in 4.3.5.18 also apply to railroad crossings. These may be modified by the railroad authorities. See fig 46 and 47 for typical examples. 4.3.5.20 Waterway crossings These crossings shall be made in accordance with the requirements of the Authorities concerned. If the waterway is navigable, it is advisable to provide notices indicating the presence of the pipeline and to prohibit anchoring. For typical example of waterway crossing see Fig 48. 4.3.5.21 Overhead crossings The crossings referred to in 4.3.5.18 to 20 may also be made by existing or purpose designed bridges. The design and construction of these crossings shall take into account requirements of Authorities concerned and local conditions affecting safety of the pipelines, e.g. minimum clearance height and associated warning notices. 4.3.5.22 Crossing or running alongside underground services The spacing and nature of construction shall be such that no mutual interference is to be expected, also that cathodic protection installation and the possibility of repair are preserved. Any agreement shall be obtained from the owners of the installations concerned. In the absence of rules the distances shown in Table Xlll may be used for typical examples see Figs 49 to 53.
1982
Page 39 of 65
IGC
Table XIII - CLEARANCE FROM UNDERGROUND SERVICES Distance in metres between outside lines Type of Works Metal pipework for hydrocarbons, gas, water, etc. Concrete or fibrocement pipework Telecommunication lines Electricy cables If these distances, cannot be observed, protection must be provided by: Crossing 0.60 m 0.40 0.40 m 0.50 m split shells of concrete for a length of 2m centred on the point of crossing and wrapped in weak concrete. Running Parallel 0.60 m 0.40 m 0.40 m 0.50 m split shells of concrete or thick, strong slabs of concrete or fibrocement. Prefabricated of cast in situ
Earthing Low or medium voltage < (15.kv) High voltage < 110Kv Lightening protectors Anode of cathodic protection
Distance in metres between outside of pipeline and earthing point 2 5 10 to be specified
4.3.5.23 Crossing drains When crossing drains or irrigation systems, special care shall be taken to ensure that their efficiency is not impaired. For typical example see Fig.51. 4.3.5.24 Proximity of overhead high tension cables Oxygen pipelines are generally laid in industrial regions where the density of high tension electricity lines is also considerable. Contact shall be made with those responsible for the electrical distribution network when a pipeline is being planned. The study to be made shall take account of the characteristics of the electricity line and of the pipeline as well as the resistivity characteristics of the ground. Subject to the results of the study, the following minimum distances and measurements are given for guidance for lines up to 110 kV without guard line and above 110 kV with guard line in Table XIV. For typical example see fig 52 and 53.
1982
Page 40 of 65
IGC
ITEM
TABLE XIV - CLEARANCES FROM HIGH TENSION OVERHEAD CABLES Minimum distance between pipeline and items In Metres Between Pipeline and : H T cable running parallel Base of pylon crossing * special case Overhead electric rail pylon crossing or running parallel Earth connection from the end of the connection Between Accessories such as valves AND H.T. CABLES Crossing or running parallel Between Vent Pipes and H.T. Cable Crossing or running Parallel Over 110 kV Under 100 kV Minimum distance between pipeline and vertical projection or extreme cable In Metres 10 10 (2) 2 3
10
30 10
Other measuresFor a pipeline in course of construction, sections that are ready welded and situated in the immediate vicinity of a high tension cable shall be earthed. Above-ground parts of a pipeline that are not covered and that are accessible and could be touched for example from the ground or from a bridge shall be electrically insulated. Any conductive connection between the pipeline and high tension line pylons is prohibited. Neutral conductors or protecting conductors of local electric distribution networks shall not be connected to the pipeline. 4.3.5.25 Construction in the proximity of high tension cables In the course of construction of the pipeline contact with a cable represents the greatest danger to personnel. Contact between site machinery and a high tension cable shall therefore, be avoided. A minimum distance of 5 m shall be respected and this distance shall take into account swaying of cable due to the wind.
1982
Page 41 of 65
IGC
4.3.5.26 Above-ground sections If the pipeline includes above-ground sections, it will be necessary for the layout of the pipework to take account of possible expansion. If the layout is inadequate for the adsorption of expansion and contraction it will be necessary to provide either expansion bellows similar to those described in section 3.5.2 or loops arranged either horizontally or vertically upwards. (Loops directed downwards present a risk of forming receptacles for dust). If the above-ground section of a pipeline is under Cathodic Protection, it will be necessary to provide electrical insulation between the pipeline and its supports. Special consideration shall be given to environmental and other conditions which may exist, such as lighting, wind, heat, corrosive atmospheres, other installations. Dangerous projected bodies etc. If the pipe is not under Cathodic Protection, it will be necessary to ensure efficient earthing. To avoid underlying corrosion, the above ground section should not be externally wrapped with a material which has a tendency to deteriorate in the atmosphere. If necessary, existing coating should be removed, and the Darts exposed to the air shall be painted.
4.3.6
Pipeline Cleaning
It is essential that a pipeline for oxygen service is in a clean condition in accordance with the requirements of 2.3. Pipe for construction of the pipeline may be: Descaled, degreased and passivated at the manufacturers works Descaled, degreased and passivated on site just prior to erection Uncleaned pipes. The methods of cleaning depend upon the condition of the line, and are described in 2.3.7.
4.3.7
4.3.7.1
Tests
Strength test The pipeline shall undergo a strength test, preferably pneumatic, using dry, oil-free air or nitrogen so as not to contaminate it. The pressure shall be increased gradually and time allowed for equalisation of pressure. The dangers inherent in performing a pneumatic test shall be recognised and adequate precautions taken. Pneumatic testing cannot be permitted unless the pipes have undergone hydraulic testing before installation adn the welds inspected in accordance with the provisions of paragraphs 4.3.5.7 to 4.3.5.11 inclusive. The test pressure, duration and procedure is generally specified by the legislation in force in the country where the pipeline is laid. Where such legislation does not apply see 4.1.9. Leak tightness test Following the strength test a test for leak tightness shall be carried out, the pressure, duration and procedure for which shall be as specified by the legislation in the country where the pipeline is laid. In the absence of such legislation, the test duration shall be a minimum of 24 hours. Typical test procedures Typical examples of performing tests are indicated in figure 54. The records of above tests shall be kept and signed by responsible persons.
4.3.7.2
4.3.7.3
1982
Page 42 of 65
IGC
4.3.8
Cathodic Protection
In order to ensure preservation of underground oxygen pipelines, they shall be protected by cathodic protection. In addition to the passive protection provided by the insulating coating applied to the outside of the pipes it will be necessary to ensure active protection by sacrifical anode or impressed current systems. The planning of this cathodic protection shall be carried out by specialists who will take into account chemical or electrical influence of the soil, also the possible effects from other installations. The potential tappings shall be welded onto the pipeline during laying. Typical example shown in figure 55. The tappings shall be properly insulated electrically from the soil. Electric cables shall be brought together beneath a capped opening or in a terminal box. In the case of highway or railway crossings, typical example of installations are indicated in fig 55. Tappings on an oxygen pipeline in service will not be done by welding but by means of a collar. Typical example is shown on Fig 57.
4.3.9
Restoration of the Terrain

Before commencement of work, a contractual record of the state of the site shall be made. The land over which the pipeline has been installed shall be reinstated to the satisfaction of the landowner or Authorities.
4.3.10 4.3.11
Pipeline Identification
Pipeline identification shall be in accordance with 5.1.
Pre-Commissioning Tests
The pipeline shall have been installed, tested and inspected as described in this code and the relevant specifications. All defects revealed during inspection and testing shall have been rectified before putting into service see 6.2.
4.3.12
As Built Drawings
When the pipeline installations completed, the drawings shall be brought up to date in accordance with any modifications that may have occurred during the installation. The information for updating of drawings shall be collated as the work proceeds.
4.3.13
Supervision of the Work Site

The supervising personnel shall ensure that the recommendations of this code are followed and in particular, shall personally verify : that the pipes are properly furnished with end plugs when they arrive on the site that there is nothing left inside the pipes when they are placed alongside for welding that each section of pipe is properly plugged tight every evening and put on blocks so that water or moisture cannot penetrate to the inside. that when work is recommenced each morning, nothing has been placed inside the end pipes. that in the event of water rising in the trench, for instance as a result of heavy rainfall, everything possible is done to prevent water from getting into the pipes, whether assembled or not. In addition, supervision during the following operations is recommended. the passage of the holiday detector the fitting of pipeline ballast lowering into the trench passing pipes through sheathing insulation coating of the potential tappings welded on the pipeline the first part of the filling of the trench introducing and removal of the pigs testing final purging Finally, the welding record shall be inspected to see that it is properly made.
1982
Page 43 of 65
IGC
Fig 41 BURIED PIPELINES Typical Cross Section of Trench
1982
Page 44 of 65
IGC
Fig 42 BURIED PIPELINES Typical Road Crossing without Sleeving or Longitudinal Utilisation of Roadway Laid in Open Trench
The depth of 1 m for covering is a minimum figure. It may be increased in accordance with the requirements of the authorities or organisations responsible for the road way.
1982
Page 45 of 65
IGC
Fig 43 BURIED PIPELINES Typical Road Crossing in Sheath of Concrete Laying by Boring or in Open Trench
1982
Page 46 of 65
IGC
Fig 44 BURIED PIPELINES Typical Road Crossing in a Metal Sheath Laying by Boring or in Open Trench
1982
Page 47 of 65
IGC
Fig 45 BURIED PIPELINES Typical Sheaths: End Seals and Centering Clamps
I D of sheet = (OD of pipe + coating) + 10 cm minimum. Distance between packing pieces according to nom. dia. of pipe. Distance between end packing pieces and end of sheath: less than 0.50 m. Packing pieces and end seals shall be of a type approved by the Site Foreman. If use is made of packing pieces made up of tarred glass wool, they must be 4 - 5 cm thick and consist mainly of fabric (50 turns per pad) and the tar must be coal tar. Thickness of steel sheath: This must be not less than: 4.5 mm up to 175 mm nom. dia. Inclusive 5 mm from 175 to 225 mm nom. dia. Inclusive 6 mm above nom. dia. 225 mm The pipelaying company shall check the mechanical strength of the sheath during and after laying.
1982
Page 48 of 65
IGC
Fig 46 BURIED PIPELINES Typical Rail Crossing Laying by Boring or in Open Trench
1982
Page 49 of 65
IGC
Fig 47 TYPICAL RAIL CROSSING With Reinforced Concrete Channels (Coal Tar Ends Seals)
1982
Page 50 of 65
IGC
Fig 48 BURIED PIPELINES Typical Waterway Crossing Laying in Mud
Note: The length of the part covered by bacula (laths) may be increased if the bottom of the trench is stoney
1982
Page 51 of 65
IGC
Fig 49 BURIED PIPELINES Typical Crossing of an Underground Pipeline Proximity of pipeline CROSSING ABOVE OR BELOW
MINIMUM SPACING E Proximity of pipeline metallic Crossing Running parallel NOTE 1: NOTE 2: 0.60 m 0.60 m Non-metallic 0.40 m 0.40 m
The warning device may be omitted if the pipelines are in sheaths or protected by split concrete shells. E may be increased if required by owner of the pipe being crossed.
1982
Page 52 of 65
IGC
Fig 50 BURIED PIPELINES Typical Crossing of an Underground Electric Power Cable or Telecommunications Cable CROSSING ABOVE OR BELOW
Proximity of Cable Minimum spacing Crossing Running parallel 0.40 m 0.40 m 3m 0.50 m 0.50 m 5m
Reinforcement of coating on both sides of crossing NOTE 1: NOTE 2:
The warning device may be omitted if the pipeline is in sheath or protected by concrete split shells. E may be increased if required by the owner of the cable being crossed.
1982
Page 53 of 65
IGC
Fig 51 BURIED PIPELINES Typical crossing of a Stoneware Drain
1982
Page 54 of 65
IGC
Fig 52 INDICATED DISTANCES BETWEEN PIPELINES AND HIGH TENSION TRANSMISSION CABLES
1982
Page 55 of 65
IGC
Fig 53 BURIED PIPELINES Proximity of an Earth Connection for an Electrical Installation of less than 110 kV
1982
Page 56 of 65
IGC
Fig 54 TRANSPORTATION PIPELINES Typical Sequence of Tests
1982
Page 57 of 65
IGC
Fig 55 BURIED PIPELINES Details of Fittings at Ends of Sheaths
1982
Page 58 of 65
IGC
Fig 56 BURIED PIPELINES Installations and equipment to be provided for crossings of highways, railways and waterways CROSSINGS SHEATHING CAPPED OPENING 2 per crossing at the boundary on each side VENT & AERATION PIPE 2 CABLE & POTENTIAL TAPPING 2 potential tappings, each comprising 1 cable of 16mm2 & 1 cable of 35mm2 REMARKS
Railways
Reinforced concrete or metal cement 2m each side of the outer boundary or 13m the nearest rail if the overall width is very large Concrete, reinforced concrete, asbestos or metal cement conduit, ending + 1m beyond the overall width at both ends Metal sheath if boring demanded by Highways Authority. Ends at boundary
Railways regulations to be applied
As required
As required
As required
If a capped opening is not provided, there must be provided at each end: a sand funnel a marker
Highways
1 per sheath of less than 30m 2 per sheath of 30m or more
As required
1 up to 30m (1 cable of 16mm2) 2 over 30m (each with 1 cable of 16mm2 and 1 cable 35m2)
Waterways Canals
Waterways or canals are usually crossed in the mud or aerially. In the event of boring they shall be made as in the case of highways with metal sheathing.
NOTE: A potential tapping be provided at least every 2km
1982
Page 59 of 65
IGC
Fig 57 POTENTIAL TAPPING BY MEANS OF A CLAMP
1982
Page 60 of 65
IGC
4.4
4.4.1
Supply Stations
General
Supply stations are normally situated on the site of production plants and receive oxygen direct from compressors or liquid evaporators. Downstream of the supply station the transportation pipeline begins. See Fig 1.
4.4.2
Function
The normal function is to allocate oxygen to one or more pipelines to suit the pressure and flow requirements. Metering facilities can also be included. See Fig 2.
4.4.3
Construction
The choice of materials and equipment and the construction of the installation shall comply with the recommendations of Parts 2 and 3 and in 4.1 and 4.2 supplemented by the following. Supply stations comprise stop valves and assemblies similar to those of distribution stations. See 4.5 and 4.6. Commissioning is dealt with in Section 6.2.
4.4.4
Special Considerations
Three points peculiar to supply stations are emphasised: a) It is recommended to protect the supply station against backflow of gas from the pipeline. b) Where liquid supplies the pipeline, precautions shall be taken to prevent low temperature gas or liquid damaging the pipeline. c) The plant may, in certain cases, receive oxygen from the pipeline via the supply station. The station shall then be designed accordingly, in particular it will generally be necessary to provide a filter.
4.5
4.5.1
Valve Stations
General
Valve stations are normally located: at branches of the pipeline at the exit from plants at recompression points at buffer stations to isolate sections of pipeline In the case of pipelines of great length, it is recommended that a valve station be installed every 30 to 35 km.
4.5.2
Function
The primary function of a valve station is to isolate one part of the installation from another. In addition, it may: facilitate maintenance operations enable pressurisation or depressurisation of sections of the pipeline. The station may be designed to function in one direction only but very often may be used to effect separation in both directions.
4.5.3
Construction
The choice of materials and equipment and the construction of the installations shall comply with the recommendations of parts 2 and 3 and in 4.1 and 4.2 supplemented by the following. Assembly and use of the stations shall take into account the characteristics of the valves, such as the degree of gas-tightness, gas-tightness in one or both directions, opening speed, etc. See Fig 58 for diagram of typical installation.
1982
Page 61 of 65
IGC
If the valve station has a by-pass or a vent to atmosphere, the pipeline and components of these parts shall be of copper or copper alloy. For vent valves see 3.6.1.22 and 4.2.5.13. Cathodic protection is dealt with in 4.2.5.15. Commissioning is dealt with in section 6.2.
4.5.4
3-valve block and bleed systems are used to safely isolate sections of pipeline where frequent work is carried out. Fig 58d. The valves may be automated. It is necessary to fit valves which are gas-tight in both directions under all operating conditions. Valves which require gas pressure to assist in providing positive shut off (e.g. certain types of gate valve) shall not be used since any leakage through the upstream valve may split between the vent valve and the downstream valve into the pipeline being protected. Fig 58 DIAGRAMS OF TYRES OF VALVE STATION
4.6
4.6.1
Distribution Stations
General
Normally, the pipeline system delivers to several distribution stations which are located on or near customers premises. (See Fig 2). Distribution stations are an essential part of the pipeline networks, having components in continuous operation (control valves, meters).
1982
Page 62 of 65
IGC
4.6.2
Function
The normal function of the station is to control flow and pressure of oxygen prior to distribution to the delivery points and to meter the quantities supplied. The other functions are generally connected with safety or operational requirements such as: filtration flow limitation protection against over-pressure venting emergency shut down The components and functions vary from case to case and are determined by careful analysis of the requirements of the station.
4.6.3
Construction
The choice of materials and equipment and the construction of installations should comply with the recommendations of parts 2 and 3 and in 4.1 and 4.2 supplemented by the following. Commissioning is dealt with in section 6.2.
4.6.4
For reasons of safety, certain uses of oxygen (e.g. chemical and petrochemical) demand a continuous supply without interruption. It is possibly necessary in such cases to provide 2 parallel systems with automatic transfer. In such cases, security of electric or pneumatic services shall also be ensured.
4.6.5
Protection of Customers Network

Care shall be taken to ensure that users network can accept the increase in pressure due to the operational characteristics of the distribution station.
4.7
Recompression Stations
Recompression stations are used to compensate for loss of pressure in the pipeline or to supply at a higher pressure than the pipeline. Such stations normally include: intake station comprising filtration and regulation of flow and pressure. See 4.6 supply station. See 4.4 general by-pass For the installation of recompression machines, the following documents may be consulted: For centrifugal compressors. Turbo compressors for Oxygen Service published by the I.C.C. for oxygen turbocompressor safety. For reciprocating compressors: Code of Practice for Reciprocating Oxygen Compressors published by the Industrial Cases Committee under No 10/81
4.8
Pressure Reduction Stations

Pressure reduction stations are used for supplying network branches at a pressure which is lower than that of the main pipeline. These stations are similar to distribution stations but are usually without metering. They shall comply with 4.6.
1982
Page 63 of 65
IGC
4.9
4.9.1
Storage Vessels (Buffers)

General
Buffers may be used: a) to provide a limited reserve supply, normally via a regulating station. See 4.6. b) to provide for intermittent use for continuous production (as in the case of oxygen for steelworks converters). The buffer being connected permanently to the network.
4.9.2
Construction of Buffers
The choice of materials and equipment and the construction of installations shall comply with the recommendations of Parts 2 and 3 and in 4.1 and 4.2 supplemented by the following. Commissioning is dealt with in Section 6.2.
4.9.3
4.9.3.1
Design
Regulations and design Buffers for oxygen storage shall be designed and constructed in accordance with the pressure vessel regulations in force in the country of use. The choice of materials, the design and the calculations must take into account the cyclic variations of pressure. Design shall also take account of additional weight during hydrostatic testing. Design pressure The design pressure shall be selected as a function of the network design conditions. (buffers shall be protected by a safety valve). Piping connections To prevent entrainment of dust and impurities, inlet, outlet and vent connections on vessels shall be situated at a height of at least 0.5 diameter of the vessel above the bottom of the vessel. If inlet, outlet or vent pipes pass through the base, they shall extend inside the vessel to a minimum height of D/6 (D = inside diameter of the vessel). The lowest part of the vessel shall include a connection (100 to 200mm dia) designed for easy removal of any deposits during inspection that may possibly have collected at the bottom of the vessel. Flange connections Flanges for pipe connections and manholes etc. shall comply with the appropriate regulations and recommendations of 3.4.1. Stop valves and vent valves Stop valves and vent valves shall comply with the recommendations in section 3.6.1 Safety valves Safety valves and their installation shall comply with the section 3.6.7 and item 4.2.5.4. Manholes Large capacity buffers and those that are installed vertically should have two manholes, one at the bottom and one at the top of the vessel, to facilitate inspection and maintenance and in the event of such work they will facilitate ventilation of the interior atmosphere. Ladders and attachments Large vertical vessels may be equipped with outside ladders to give access to manholes and with inside ladders or spurs for inspection and maintenance. Any internal attachments should be made from solid bar welded to the wall of the vessel to avoid movement and vibration. Permanent inside ladders constructed by mechanical assembly are prohibited.
4.9.3.2
4.9.3.3
4.9.3.4
4.9.3.5 4.9.3.6 4.9.3.7
4.9.3.8
1982
Page 64 of 65
IGC
4.9.4
4.9.4.1
Inspection and Cleaning

Inspection and tests National regulations generally require for inspection and material certificate for the Construction of pressure vessels, as well as for hydraulic tests. Hydraulic strength tests shall be carried out with potable (drinking) water free from oil or grease. Cleaning After hydraulic testing and drying with clean oil free dry nitrogen or air, the interior shall be cleaned in accordance with the recommendations of 2.3.5. The cleanliness shall be verified according to the recommendations of 2.3.8.3. Sand blasting is recommended, followed by cleaning in accordance with 2.3.5.4. If necessary, traces of oil or grease shall be removed by the use of a solvent recommended in section 2.2.2 and a clean rag according to 2.2.4.5. After cleaning, the vessel shall be filled with a nitrogen and all connections carefully sealed in accordance with the recommendations of 2.3.9. External finish Painting of the outside shall not be carried out until all the connections of the vessel have been closed.
4.9.4.2
4.9.4.3
4.9.5
4.9.5.1
Installation
Foundations and supports Supports for buffers may be made of metal frames or reinforced concrete. They shall be solidly anchored to stablp foundations. The design of supports and foundations shall be based on-: The weight of the vessel when filled with water in case of hydraulic testing in situ Wind loading The expansion and contraction of horizontal vessels The area of contact between the buffer and supports shall be designed to avoid the possibility of hidden corrosion. Valves and controls Where valves and controls are installed in conjunction with oxygen buffers the recommendations of 4.2.1 and 4.2.2 should be observed.
4.9.5.2
1982
Page 65 of 65
IGC
IGC 13/82 The Transportation and Distribution of Oxygen by Pipeline Part 5 : Signs and Information
The Transportation and Distribution of Oxygen by Pipeline Part 5 : Signs and Information
IGC 13/82/E
1982
Page 1 of 7
IGC
SECTION 5 : SIGNS AND INFORMATION .....................................................................................................3 5.1 PIPELINE ROUTE MARKERS .......................................................................................................................3 5.1.1 Purpose..............................................................................................................................................3 5.1.2 Marker Posts......................................................................................................................................3 5.1.3 Markers for Aerial Inspection............................................................................................................3 5.1.4 Underground Markers .......................................................................................................................3 5.1.5 Above Ground Markers .....................................................................................................................3 5.1.6 Pipeline Corridors .............................................................................................................................3 5.2 STATION SIGNS .........................................................................................................................................4 5.2.1 Purpose..............................................................................................................................................4 5.2.2 General Sign ......................................................................................................................................4 5.2.3 Instructions to Operators...................................................................................................................4 5.2.4 Safety Signs........................................................................................................................................4 5.2.5 Colour of Sign....................................................................................................................................4 5.3 RECORDS ..................................................................................................................................................4 5.3.1 Purpose..............................................................................................................................................4 5.3.2 Agreement Documents .......................................................................................................................4 5.3.3 Design and Inspection Documents ....................................................................................................5 5.3.4 Design Drawings As Built .............................................................................................................5 5.3.5 Modifications .....................................................................................................................................5 5.3.6 Records to Authorities .......................................................................................................................5 5.4 LAND ADMINISTRATION............................................................................................................................5 5.4.1 Purpose..............................................................................................................................................5 5.4.2 Action.................................................................................................................................................5 5.5 INFORMATION - INSPECTION - EMERGENCY PLAN ....................................................................................6 5.5.1 Purpose..............................................................................................................................................6 5.5.2 Information ........................................................................................................................................6 5.5.3 Inspection ..........................................................................................................................................6
5.5.3.1 5.5.3.2 Regular inspection ........................................................................................................................................6 Special information ......................................................................................................................................6
5.5.4
5.5.4.1 5.5.4.2
Emergency Plan.................................................................................................................................7
Use of the emergency plan ...........................................................................................................................7 Content .........................................................................................................................................................7
1982
Page 2 of 7
IGC
SECTION 5 : SIGNS AND INFORMATION

5.1
5.1.1
Pipeline Route Markers

Purpose
Where pipelines are underground it is necessary to provide markers to identify the route, to facilitate inspection and to warn any others likely to undertake operations in the immediate vicinity. This marking is important, to prevent damage by civil engineering machinery during digging operations.
5.1.2
Marker Posts
Marker posts indicate at ground level existence of the installation, and shall be provided at intervals (eg 200 to 500 meters) and along the entire length of the buried pipeline. Locations changes of direction crossings, roadways, railways and waterways. the point where pipelines or other underground services cross. special points. Marker plates shall be fixed to the marker posts or other suitable supports and be positioned so that they can be easily found. A typical marker plate is illustrated in fig 59. This plate indicates: the name of the owner oxygen pipeline diameter and pressure pipeline distance from the marker the depth at which the pipeline is buried. Placing of the markers shall be properly carried out so as not to be effected by ground movements. Positions shall be chosen with a view to avoiding damage or destruction of the-markers. They shall not constitute an obstacle to the use of the land. The position of markers shall be indicated, on the appropriate survey map for the installation.
5.1.3
Markers for Aerial Inspection

In the event of inspection by aerial survey it is advisable to provide along the length of the pipeline markers that can be spotted from a height of approximately 200 to 300 meters.
5.1.4
Underground Markers
In certain areas it is advisable to place a warning grid or tape over the pipeline. (see 4.3.5.17). In particular areas the grid or tape may be replaced by concrete slabs which in addition to marking provides protection.
5.1.5 5.1.6
Above Ground Markers

Above ground section of pipeline shall be clearly identified by suitable markings. See 5.2.5.
Pipeline Corridors
In some highly industrialised areas pipelines may have to make use of reserved pipeline corridors. In this case marking shall be suitable for the corridor and it will be necessary to comply with the rules imposed
1982
Page 3 of 7
IGC
5.2
5.2.1
Station Signs
Purpose
The purpose of these signs is to provide: warning of the type of installation information concerning safety instructions to operators
5.2.2
General Sign
This sign should indicate: the name of the owner the responsible local branch the telephone number to call the fluid transported (oxygen) and identification of station, precise location. The sign may indicate the hospital for emergency service. This sign shall be placed in a prominent external position.
5.2.3
Instructions to Operators
A simplified diagram of the station shall be displayed, with a list of manual operations for putting into operation and shut down, for typical example see fig 60. The diagram shall be located inside, near the main entrance, or inside the control room in case of distribution stations.
5.2.4
Safety Signs
Safety signs draw attention to prohibitions and recommendations Prohibitions Access Smoking Use of naked flames Use of oil and grease Recommendations Protective equipment For typical signs see fig 61. These signs shall be placed in a prominent position at the entrance to the station and if necessary at several locations in the case of large stations.
5.2.5
Colour of Sign
Standard or statutory colours shall be used.
5.3
5.3.1
Records
Purpose
Pipeline installations are recorded on appropriate survey maps, and records shall also indicate where use is made of public or private properties and indicate where rules are imposed. These records shall be readily available for reference.
5.3.2
Agreement Documents
These documents are: way leave agreements for the pipeline and ancillary installations: permission to instal pipeline. permission to operate pipeline. The form of the agreements will depend upon the regulations in force.
1982
Page 4 of 7
IGC
5.3.3
Design and Inspection Documents

The records shall include the documents previously mentioned in the Code, such as: design calculations test certificates and inspection reports material conformity certificates welder approval certificates weld test document (X-ray) pressure test certificates
5.3.4
Design Drawings As Built

The final design drawings entered in the records shall take into account any modifications made in the course of installation. See 4.3.12. The records shall comprise: a route map identification of property owners ordinance survey maps with reference points, distances, outline diagrams etc plans of crossings of: main highways and motorways secondary roads railways, rivers and canals private roadways location of marker posts location of cathodic protection test points ground contours design drawing of special installations with supporting calculations drawings showing design and location of station including cathodic protection
5.3.5 5.3.6
Modifications
Details of all modifications and repairs, shall be incorporated into the drawings and records.
Records to Authorities
Documents required shall be forwarded to the authorities as necessary.
5.4
5.4.1
Land Administration
Purpose
The ability to install the pipeline may be subject to numerous land agreements. These agreements are frequently subject to special clauses and require administrative procedure of a legal nature, the purpose of which is to safeguard the installation.
5.4.2
Action
The purpose of initial action is to legalise the agreements. Later it is mainly a matter of keeping up with modifications of land ownership due to purchases, transfer, regroupings and road or rail projects and other developments. It is also important to ensure a constant review of all works and developments planned in the vicinity of the installations. This is necessary to safeguard the interests of the owner of the installation and impose safety conditions. This procedure is also connected with the problems of supervision dealt with in 5.5 and with the problems of maintenance modifications dealt with in 6.4 and 6.5.
1982
Page 5 of 7
IGC
5.5
5.5.1
Information - Inspection - Emergency Plan

Purpose
To reduce the number of accidents due to ignorance of the existence of pipeline networks. By effective information and inspection. The object of the emergency plan is to define and implement actions following any emergency.
5.5.2
Information
In the case of large or complex pipeline installations it is useful to prepare a map showing the route and the names of the areas traversed. Mention may also be made of: the dangers that may result from damage to an oxygen pipeline by earth - moving equipment. An instruction to contact pipeline operator where work is to be carried out in close proximity to the pipeline. The address and telephone number of the place to contact for information. It is advisable to implement procedures, which ensure that where necessary information is passed to all who may be concerned such as: Public utilities (fire, gas, electric, water and telephone) Local authorities concerned Companies and other land owners traversed Others (civil engineers, lawyers and surveyors)
5.5.3
Inspection
A distinction is made between regular and occasional inspection. Certain technical aspects of inspection are dealt with more fully in section 6 of the Code.
5.5.3.1
Regular inspection The pipeline should be inspected on foot at least once a year. Other complimentary inspections can be carried out by car, plane or helicopter. A general inspection of the route should be made every 6 months, and more often in areas subject to frequent work by others or earth subsidence and anomalies reported. The inspector shall: in case of immediate and obvious risk, indicate measures to be taken to avoid an accident. give the contractor the address of the person responsible for the pipeline. inform his company of any anomalies of work being carried out by others in the vicinity of the pipeline. The inspectors report shall include the following information: any damage to the installations, pipelines - leaks, corrosion, physical damage, exposure of buried piping. accessories, sheathing, inspection covers, cathodic protection, markers. supports and supporting structures earth movements (especially in mining areas) at river banks or mountains. works in progress along the route adjacent to the pipeline. changes liable to affect the installations, planting of trees, area development industrial or private. particular attention shall be given to areas where leaks could enter confined spaces, i.e. sewers, and caves. Following inspections it may be necessary to update survey maps. Special information Inspection is recommended when works are being carried out in the immediate vicinity of the installation where on-site co-operation and guidance are necessary. It is also advisable to send the contractor recommendations concerning precautions to be observed. This last point is dealt with in 6.1.
5.5.3.2
1982
Page 6 of 7
IGC
5.5.4
5.5.4.1
Emergency Plan
Use of the emergency plan An emergency plan is recommended for large scale or complex systems, it should contain essential identification for the network and emergency actions to be taken. The emergency plan should be at the disposal of the system oxygen plant managers of maintenance managers and of other concerned with the operation of the pipelines. In certain cases this document may also be required by the National Authorities, Local Authorities, police, fire department and safety organisations etc: Content The emergency plan shall comprise the following information: a general description of the system action to be taken in case of emergency persons to contact action to be initiated. the area addresses and telephone numbers of: Companv plant and personnel responsible the police the fire brigade the hospital authorities the customers description of the system: a detailed map of the system details of location and access to stations a flow diagram of the system design specification, diameter, pressure etc flow diagram of the stations the means of taking action: the location of emergency equipment and vehicles the addresses and telephone numbers of contractors trained in emergency operations emergency instructions a reminder of the main safety rules for oxygen oxygen data sheet According to circumstances the system may be divided into areas and documented accordingly. The emergency plan shall be kept up-to-date.
5.5.4.2
1982
Page 7 of 7
IGC
IGC 13/82 The Transportation and Distribution of Oxygen by Pipeline Part 6 : Operations and Maintenance
The Transportation and Distribution of Oxygen by Pipeline Part 6 : Operations and Maintenance
IGC 13/82/E
1982
Page 1 of 14
IGC
SECTION 6 : OPERATIONS AND MAINTENANCE ......................................................................................3 6.1 GENERAL SAFETY RULES..................................................................................................................3 6.1.1 Basic Rules ........................................................................................................................................3
6.1.1.1 6.1.1.2 6.1.1.3 6.1.1.4 Operations and maintenance personnel ........................................................................................................3 Operation of stop valves ...............................................................................................................................3 Cutting and welding work ............................................................................................................................4 Rules and recommendations - general and special .......................................................................................4
6.1.2
6.1.2.1 6.1.2.2 6.1.2.3
Protection Against Oxygen Enrichment & Deficiency.......................................................................5

Limit thresholds............................................................................................................................................5 Measurement and control of oxygen concentration......................................................................................5 Isolation of circuits.......................................................................................................................................6
6.1.2.3.1 6.1.2.3.2
6.1.2.4
General rules ......................................................................................................................... 6 Practical points to note .......................................................................................................... 6 Venting .................................................................................................................................. 7 Depressurising....................................................................................................................... 7 Purging .................................................................................................................................. 7 Extraction of residual oxygen from pipelines........................................................................ 7 Ventilation............................................................................................................................. 7
Venting to atmosphere, depressurising, purging...........................................................................................7
6.1.2.4.1 6.1.2.4.2 6.1.2.4.3 6.1.2.4.4 6.1.2.4.5

6.1.2.5 6.1.2.6 6.1.2.7
Work inside buildings...................................................................................................................................7 Work within storage vessels .........................................................................................................................7 Work in trenches ..........................................................................................................................................8
6.1.3
6.1.3.1
Clothing and Cleanliness of the Hands .............................................................................................8

Clothing........................................................................................................................................................8
6.1.4
6.1.4.1 6.1.4.2
Tools and Handling ...........................................................................................................................9

Tools.............................................................................................................................................................9 Handling.......................................................................................................................................................9
6.1.5 Preparation for Work ........................................................................................................................9 6.1.6 Co-ordination of Third Party Work ...................................................................................................9 6.2 COMMISSIONING .....................................................................................................................................10 6.2.1 Compliance With Recommendations ...............................................................................................10 6.2.2 Inspection Before Commissioning of Installations ..........................................................................10 6.2.3 Pressurising .....................................................................................................................................10 6.2.4 Nitrogen Pockets..............................................................................................................................10 6.3 OPERATION .............................................................................................................................................11 6.3.1 Compliance with Recommendations................................................................................................11 6.3.2 Operating, Alarm and Tripping Devices .........................................................................................11 6.3.3 Filter Cleaning ................................................................................................................................11 6.4 MAINTENANCE AND INSPECTION ............................................................................................................11 6.4.1 Compliance with Recommendations................................................................................................11 6.4.2. Pipeline Maintenance ......................................................................................................................12 6.4.3 Component Maintenance .................................................................................................................12 6.4.4 Special Inspections ..........................................................................................................................12
6.4.4.1 6.4.4.2 Severely stressed areas of buried pipelines.................................................................................................12 Effect of an incident ...................................................................................................................................12
6.4.5 Locating a Leak on an Underground System...................................................................................13 6.4.6 Drying a Pipeline.............................................................................................................................13 6.4.7 Programme of Preventive Maintenance and Inspections ................................................................13 6.5 MODIFICATIONS ......................................................................................................................................13 6.6 WITHDRAWAL FROM, OR CHANGE OF, SERVICE .....................................................................................14 6.6.1 Compliance with Recommendations................................................................................................14 6.6.2 Possible Cases .................................................................................................................................14
6.6.2.1 6.6.2.2 6.6.2.3 6.6.2.4 Taking out of service ..................................................................................................................................14 Removal of pipeline ...................................................................................................................................14 Changing from oxygen to another gas........................................................................................................14 Change to oxygen service from another product ........................................................................................14
1982
Page 2 of 14
IGC
SECTION 6 : OPERATIONS AND MAINTENANCE

In the preceding sections the choice of equipment and the design of the installations have been examined. Where the precautions to be taken relate to the safe use of the installation with oxygen. However when the installations are taken into use, dangers do exist and these are dealt with together with precautions necessary for the safe operation and maintenance as well as inspection.
6.1
6.1.1
6.1.1.1
GENERAL SAFETY RULES

Basic Rules
Operations and maintenance personnel In accordance with 1.7.3, personnel assigned to the operation and maintenance of oxygen installations shall have received adequate training. Personnel shall have a good knowledge of the location and design of the installations, and shall be given operation and safety instructions in writing. Main safety instructions shall be displayed at the places of work (see 5.2). In the event of repair work carried out by outside contractors such personnel shall be supervised to ensure that safe operational procedures are observed. No operation involving risk shall be entrusted to any single person. An assistant acting as observer shall in case of accident be able to raise the alarm and give assistance or first aid. Operation of stop valves We have seen in 1.3.1.5 that excessive gas velocity and in 1.4.2.1.6 that high adiabatic compression may be the cause of heating that may lead to ignition. High values of P are causes of these phenomena. Although control valves are designed to operate with high P the same is not true of ordinary stop valves, which shall not be used as throttle valves. It is not advisable to open a stop valve in the presence of a high P because of throttling and high velocity effects. See 4.2.5.1.3. It is always desirable: To ensure a slow and controlled increase in pressure. to operate stop valves with: the pressure equalised on both sides the gas flow at rest. P = difference in pressure between upstream and downstream of components. These handling precautions shall be observed mainly when the system is taken into service or modified. Modifications of the system are understood to mean: modifications made to the installations such as the removal, change or addition of equipment. putting into service any new oxygen supply. modification to the operating conditions of the pipeline system: change inflow pattern, involving increased velocities and the possible displacement of dust and particles. alteration of pressure conditions. change of flow direction. There are some case
6.1.1.2
1982
Page 3 of 14
IGC
that do not fall within these basic principles. e.g. a) Operation of stop valves isolating a component When filters are installed in parallel it is necessary to inspect and clean without stopping operations. The first valve to be closed shall be the one downstream of the filter in use which is in the filtered part of the gas flow. By contrast when opening, the upstream valve shall be opening first. b) Closure of an emergency valve Some systems may be equipped with automatic valves that can be closed automatically by remote control in the event of an incident. Re-opening of these valves, however, shall be carried out locally. Following pressure equalisation. Stop valves that are rarely used shall be operated periodically to test their proper functioning, e.g. every six months. 6.1.1.3 Cutting and welding work No cutting or welding work shall be undertaken on pipelines and components containing oxygen. The only exceptions is the drilling of small holes on depressurised pipelines. This may be carried out by specially trained personnel using special procedures and equipment. Rules and recommendations - general and special These are due to the: specific properties of oxygen fact that the gas is under pressure nature of the work a) General Rules The following are the basic general rules covered by this code: only trained personnel allowed to operate observance of safety zones observance of the rules in safety zones such as: no smoking no naked flames requirement for materials and assembly of components observance at all times of the two fundamental, compulsory requirements: NO OIL OR GREASE SCRUPULOUS CLEANLINESS ensure that installations remain clean, that premises are not encumbered with unnecessary objects and that exits remain clear. report every anomaly during inspections or work on the installation any anomalies (unusual noise, change in the appearance of paint, heating, soke) shall be investigated. If there is any doubt concerning its origin, personnel shall leave the area immediately without attemtping to investigate further and report to responsible person.
6.1.1.4
1982
Page 4 of 14
IGC
b)
Special Rules Other recommendations: For night work, provide appropriate lighting in the work area and access. In stations, the lighting shall be switched on even during work in the daytime, to ensure adequate lighting in case of incident. For work at height, adequate safety precautions shall be provided. When dismantling, avoid the use of penetrating products, or if they do have to be used, ensure effective cleaning before asseirbly. The re-tightening of components or couplings in a circuit tinder pressure shall be forbidden. Circuit shall be depressurised before this work is carried out. For any work on site and for cutting, grinding and welding operations, provide the relevant protective equipment. Under no circumstances shall oxygen installations be used as an earth return during welding operations. Open ends of pipelines shall be sealed at all times unless work is in progress. Temporary pipes or components whose strength is unknown shall not be used. For supply of blowing or purging gas, use degreased, clean pipelines. Wlnen acid, caustic materials or solvents are used, provide appropriate protection (face shield, safety goggles, gloves, boots, aprons) and the necessary ventilation. Remember that chlorinated solvents can decompose and produce phosgene when heated or subjected to ultra violet rays, e.g. when welding. Wherever possible, work requiring contact with the pipelines or their components shall be avoided during electric storms. Contact with cathodic protection installations shall be forbidden during electric storms.
6.1.2
6.1.2.1
Protection Against Oxygen Enrichment & Deficiency

Limit thresholds We have in 1.3.2 indicated the dangers caused by oxygen-enriched atmospheres (danger of ignition) and in 1.3.4.3 those caused by oxygen-deficient atmospheres (danger of asphyxia). As a general rule there is no reason for working in areas where the atmosphere is not or cannot be the same as that usual in air, namely 21% oxygen, any deviation on either side of 21% constitutes an anomaly. When measuring level of oxygen the accuracy of measuring instruments shall be borne in mind: The following warning thresholds are recommended: For oxygen enrichment 22% For oxygen deficiency 19% The concentration of oxygen maybe localised, neighbouring areas may be more enriched or more deficient, a fact which urges care in taking measurements. Special care shall be taken in the case of work being carried out, inside buildings, in enclosed areas and in holes or trenches. Work in the open air generally presents little danger. Oxygen at the same temperature as air and nitrogen when its temperature is lower than air is heavier and therefore tends to accumulate at low levels. Measurement and control of oxygen concentration Variations in the oxygen concentration in the atmosphere, cannot be detected by the senses. The use of combustion tests is strictly forbidden. It is necessary in the case of operations requiring control of the atmosphere, to be equipped with instruments for measuring the concentration. Measurement of the concentration shall be undertaken at one or more points: In the pipeline upstream of the work position. In the pipeline downstream of the work position. In the work area, at carefully selected points.
6.1.2.2
1982
Page 5 of 14
IGC
There are many types of portable instruments on the market, selection shall be made with regard to the following points. accurate measurement rapid, response audible alarm signal may be incorporated suitable for use on site robust suitable for inclement weather lockable settings accuracy and response not affected by temperature not sensitive to humidity not sensitive to position Instruments shall be subjected to regular inspection and calibration. Care should be taken at altitude to reset analysers to compensate for change in atmospheric pressure. 6.1.2.3 6.1.2.3.1 Isolation of circuits General rules In 1.4.6 and 1.4.8 the main causes of oxygen enrichment or deficiency are indicated. No repair work may be carried out on a pipeline or pipeline system unless the work point is reliably isolated. In the case of maintenance during operation such as the cleaning of a filter or replacement of a component, the closure of leak-tight isolation valves is acceptable. A non-return valve cannot be considered as isolation component. In the case of works involving cutting, shaping or welding, there shall be a positive guarantee of isolation. One of the following shall be considered. Complete disconnection and isolation from the system The fitting of blind flanges Three valve block and bleed system see 4.5.4. The closure of a valve and insertion of a sealing balloon with a vent to atmosphere in between, or other procedures adaptable to the problems of large networks. Practical points to note The removal of a component or of a section of pipe without sealing off the pipeline is generally insufficient for the protection of a circuit. Existing leaks may enrich the atmosphere in the area concerned. The gas may also pass from the upstream section to the downstream section if chimney effect is established in the downstream section. The site layout shall be studied so that preventive action can be taken to avoid oxygen enrichment or deficiency due to chimney effect or wind. In the case of a long pipeline of gas rapidly, emptied of gas, and isolated upstream an oxygen flow is possible after emptying for the following reasons: Residual gas which has been cooled during the depressurisation warms up and is emitted at the open end. Heating may be caused by the ground, or by the sun on above-ground sections. Changes in level may produce a chimney effect. Variations of atmospheric pressure or density may cause flow to take place. These three effects may be cumulative. It should also be noted that: If oxygen is used to operate equipment in the stations these circuits shall be considered as a possible cause of leakage with enrichment of the atmosphere. Oxygen may also originate from the improper use of equipment (heating, cutting and welding torches).
6.1.2.3.2
1982
Page 6 of 14
IGC
6.1.2.4 6.1.2.4.1
Venting to atmosphere, depressurising, purging Venting Venting of large quantities of oxygen into the atmosphere shall be carried out under clearly defined, controlled conditions for valves used for venting see 3.6.1.22. Venting procedures shall ensure that oxygen is removed to a point where it ceases to be dangerous to personnel or surroundings. Combustion engines and compressors are particularly dangerous in an oxygen-enriched atmosphere.
6.1.2.4.2
Depressurising Depressurising small volumes of gas shall be carried out by means of suitable components (3.6.1.19 to 21). For valve stations see 3.6.1.22 and 4.5.3. Depressurisation procedures shall be clearly defined. Depressurisation by the loosening of bolts, on flanges or couplings is forbidden.
6.1.2.4.3
Purging The purging of a pipeline ensures the removal of oxygen from a system. This purging may be carried out with dry oil free nitrogen or air. If nitrogen is used for purging care should be taken see 6.1.2.
6.1.2.4.4
Extraction of residual oxygen from pipelines Consideration may be given to the protection of a working area, by extraction using suction devices in the pipeline. This method requires special procedures and equipment and shall therefore be used only by specially trained and well-informed personnel.
6.1.2.4.5
Ventilation Ventilation of an enclosure or trench may be effected by extraction or preferrably by introducing fresh air.
6.1.2.5
Work inside buildings The dangers of oxygen enrichment or deficiency are greater inside a building than in the open air. If a big leakage is found inside a building, the following steps shall be taken in the order given: Evacuate the building Do not enter Shut down the installation Isolate the installation Depressurise the installation Ventilate the building Test the atmosphere before entering the building continue testing during maintenance Repair the leak Work within storage vessels It may be necessary to undertake work inside large vessels such as buffers (see 4.9). Before work is started the vessel shall be isolated, purged and its atmosphere tested. If necessary continuous analysis shall be carried out, and a continuous supply of dry oil free air maintained.
6.1.2.6
1982
Page 7 of 14
IGC
6.1.2.7
Work in trenches Work at the bottom of an excavation may be necessary on oxygen pipeline systems for repair or modifications, fig 76. The excavation is a low point without cross ventilation, and represents a likely place for the formation of a dangerous atmosphere. In addition, it is a place where use is made of torches, grinders and welding equipment which provide sources of ignition. In any trench where there is the risk of oxygen enrichment or deficiency of the atmosphere, the following precautions shall be taken. The trench shall be constructed so as to permit the rapid evacuation of personnel by means of: sloping sides metal ladders continuous analysis of the atmosphere shall be made. A person in charge of the work shall be stationed at the edge of the trench. It shall be his duty to supervise the proper progress of operations to make any decision in unforeseen circumstances to ensure correct composition of the atmosphere to be ready to act with fire fighting equipment. See 7.2 & 7.4. If necessary, ventilation shall be provided. Fig.59 WORKING IN A TRENCH
6.1.3
6.1.3.1
Clothing and Cleanliness of the Hands

Clothing Work clothes, gloves and footware shall be in good condition, free from fluff, clean and without grease stains. Clothing should be light in colour. Clothes should be well-fitting but easy to remove. They should not have gaping pockets and trouser legs should not have turnups. Pockets should preferably have zip fasteners. Loose material and flowing garments are more easily impregnated with oxygen. Closely woven cotton and wool are recommended. Leather which has been fire-proofed is also a good product (see 1.3.2.). Certain synthetic fabrics made to be fire resistant may also be used provided tests have demonstrated their safe use. Synthetic materials are generally less flammable but when they are ignited they melt, stick to the skin and may contaminate any wounds. Synthetic fabrics are therefore not recommended for undergarments.
1982
Page 8 of 14
IGC
6.1.4
6.1.4.1
Tools and Handling

Tools The tools and accessories used (work benches, supports) shall be in good condition and clean, free from oil and grease. It is not necessary to use anti-sparking tools. If mechanical tools comprising lubricated elements are used (pulley blocks, portable grinders and drills, etc), they shall not have any seepage or ejection of oil or grease. For cleaning cloths see 2.2.4.5. For blowing gases see 2.2.5. Regarding the maintenance of components it is recommended that a specific place be reserved in the maintenance workshop for equipment used with oxygen. The bench can then be covered with light coloured paper which is periodically changed or when contaminated. Handling The handling of components and sections of pipeline shall be carried out with care, making sure that equipment and especially the faces of flange joints are not damaged. The use of slings is recommended. If mechanical handling equipment is necessary, any possible pollution by oil from cables, gears or other sources of oil or grease shall be avoided.
6.1.4.2
6.1.5
Preparation for Work

Prior to commencement of maintenance or modification work on oxygen pipeline installations, especially long or complex installations, a survey shall be carried out and the method of completing the work procedures planned, programmed, the equipment required established and safety precautions to be implemented. shutdown procedures work start-up Care shall be taken to ensure that work by, or affecting others, is co-ordinated. All personnel concerned with the work should be made familiar with the programme and supervised to verify that the work is carried out correctly, safely and to the programme. Any deviation from the planned work shall be properly authorised by the person in charge of the work. On the spot decisions by other individuals should be avoided. Work permits shall be prepared and implemented as necessary.
6.1.6
Co-ordination of Third Party Work

Co-ordination shall be carried out between the owner and third parties who have to execute operations near to pipelines or stations of an oxygen system and a work plan agreed. In 5 we have described the importance of notification of the work and in 5.5.2 the information it is necessary to provide. If any work such as digging, pipelaying or construction is to be carried out in the vicinity of the pipeline with the possible need to expose it, a note shall be sent to the third party with a plan of the route.
1982
Page 9 of 14
IGC
This note shall specify: a description of the oxygen system the need to accurately locate and identify the route of the pipeline. a request for the third party to communicate the exact date for the work so that a representative of the owner may be present to check the pegging out and the work itself. the precautions and measures to be observed during the work: if trial holes are necessary, they shall be made manually. mechanical digging work shall be supervised and prohibited in the immediate vicinity of the pipeline. Necessary precautions to be taken for the passage of heavy machines or equipment over the pipelines. the conditions for backfilling and marking a request for details of the third party work so that record drawings can be updated. the distances to be observed from the oxygen pipeline, see 4.3.5. - 22, 23 and 24 the requirements of cathodic protection The note should also give a brief indication of the dangers associated with oxygen systems. It shall specify that the drawing provided is indicative only and that verification may be necessary. Dimensions given may be inaccurate as a result of alterations following road straightening, new roads, demolitions, land boundary changes, the laying of new system, etc. For these reasons preliminary route identification is often necessary.
6.2
6.2.1
Commissioning
Compliance With Recommendations
Commissioning operations should be carried out in accordance with the recommendations of 6.1 and the special recommendations below. Commissioning instructions provided by suppliers and designers of equipment and installations shall be observed.
6.2.2
Inspection Before Commissioning of Installations

Before any installations: pipelines valve stations, distribution stations, buffers, etc., are commissioned it is essential to ensure that the installation is correctly installed, tested and clean. See 4.2.8. In the event of uncertainty with regard to cleanliness it will be necessary to effect control by dismantling and inspection. it may then be necessary to proceed to the cleaning or blowing demanded. The sequence of dismantling and blowing shall ensure that purge gas blown through pipes that have not been cleaned does not pass through valves and components. In advancing section by section, the valves and components should be removed and replaced by spools before blowing commences.
6.2.3
Pressurising
Pressurising of the installation shall be carried out progressively using throttling or by-pass valves fitted on the installation. If an installation contains several stop valves in series all these valves shall be opened using one valve only to introduce the oxygen. If the installation includes an automatic or expansion valve (3.6.2. or 3.6.4) this valve may be used.
6.2.4
Nitrogen Pockets
When nitrogen has been used, pockets may remain in the pipeline in spite of blowing through. For this reason medical installations should not be connected to industrial oxygen distribution systems.
1982
Page 10 of 14
IGC
6.3
6.3.1
Operation
Compliance with Recommendations
Installations shall be operated in accordance with the recommendations of 6.1 and 6.2 and the special recommendations below. Operating instructions provided by suppliers and designers of equipment and installations shall be observed.
6.3.2
Operating, Alarm and Tripping Devices

In normal service all the safety devices shall be operational: they shall not be put out of service, or settings altered. They shall be periodically tested. When an installation has been shut down by a tripping device it shall not be returned to service until the reason for tripping has been determined and any faults corrected.
6.3.3
Filter Cleaning
The cleaning of filters demands special care, to prevent dust collected in the filter being returned to the system. In order to remain effective, fitlers shall be regularly cleaned. From the date of entering service, the intervals between successive clearings shall not be longer than: one week two weeks, twice one month then every two months or as indicated by the differential pressure. The cleaning of filter elements in situ is not recommended. A spare filter element should be fitted and the element withdrawn cleaned in the workshop and maintained oxygen clean. Any considerable modification of the operating pattern of the system may be considered as a new commencement of operation (e.g. large increase in maximum flowrate, reversal of flow direction).
6.4
6.4.1
Maintenance and Inspection

Maintenance of the installations shall be in accordance with the recommendations in 6.1 to 6.3 and with the special recommendations below. Maintenance instructions provided by suppliers and designers of equipment and installations shall be observed. The recommendations in 4.2.7 and 4.2.8 shall also be taken into consideration in connection with maintenance work.
1982
Page 11 of 14
IGC
6.4.2.
Pipeline Maintenance
The pipeline maintenance and inspection work is limited. It may be entrusted to specialised contractors. Typical jobs are as follows: Recentering the pipe inside sheaths Renewal of pipeline insulation Repair of supports and restoration of paintwork on above-ground sections. Replacement of earth or repair to pipeline made necessary by ground movement. Repair of damage caused by adjacent works. Modifications, resulting from area development. Work on the cathodic protection system: Modification or reinforcement of the protection Repair of insulation Insertion of new anodes Provision of additional control points Repair of faults detected. Repair of cathodic protection potential taps Maintenance of support structures at road, rail and water crossings. Maintenance of above-ground sections of pipeline. Repair of damaged marker posts.
6.4.3
Component Maintenance
In the event of breakdown or malfunctioning of a component it is recommended that repair on site be avoided. It is better to remove the component and replace it with one in good working condition. Reconditioning of the faulty component should be carried out in the workshop. If repairs have to be done on site, the part of the installation concerned shall be depressurised. Adjustments to components in situ under oxygen pressure should be avoided. It is better to make adjustments using dry air or nitrogen free from oil or grease. During work dismantled elements shall be stored in a clean area and covered to prevent contamination and to protect against the weather.
6.4.4
6.4.4.1
Special Inspections
Severely stressed areas of buried pipelines In order to monitor the stress conditions of pipelines, in particular in areas where there are frequent ground movements, it may be useful to measure the state of stress of the pipe by means of stress gauges or other suitable means. The readings should be taken at regular intervals and under different climatic conditions. If the stresses exceed abnormal thresholds, corrective action shall be taken. It should, however, be noted that this condition is very rare. Effect of an incident Following an incident, particles (such as soil, cinders etc) may have been entrained or projected into the interior of the installations, both upstream and downstream. It is, therefore, advisable after an incident to thoroughly inspect the complete installation.
6.4.4.2
1982
Page 12 of 14
IGC
6.4.5
Locating a Leak on an Underground System

If it is necessary to locate a leak on an underground system, location of the leak may be a lengthy operation because there is at present no simple device able to detect easily a slight leakage of oxygen from a system. If sections of the pipeline can be isolated, a pressure drop test may be considered. If there is a leak it shall be located by sound or by successive examination of pipeline sections. In certain cases, it is possible to make use of helium or of a gas whose leakage is easily detectable. In the case of buried pipelines, however, the result of the tests is not clear if the leakage is small. In addition, in the case of oxygen the choice of tracing gas is not without restriction (see 2.2.7) The search for a leak by analysis of the oxygen content in the air along the pipeline may not be effective. If the leak is a large one it may be audible or visible during regular inspection of the pipeline. Finally, before any search for a leak it will be useful to make a general inspection of the whole route to detect any areas of working or of ground movements. The leak will usually be in these areas.
6.4.6
Drying a Pipeline
On several occasions mention has been made of the need for protecting the pipelines against the entry of water. In 4.1.9.1 also mentioned is the disadvantages of hydraulic testing, which it is advisable to avoid. It may, however, happen that as a result of an incident during working (such as sudden flooding) water may enter the pipeline. it will then be necessary to clean and dry it. The recommended procedure is as follows: a) drive out the water by means of a suitably leaktight pigging device (2.2.4.4.) Several passes are usually necessary. b) Dry with clean, dry, oil-free air or nitrogen. This operation is a lengthy one. It may be speeded up by slightly preheating the gas (50C.) c) After drying, brushing pigs should be passed (one or two passes) through the pipeline (2.3.5.5). d) Finish by blowing (2.3.5.6) Drying by adsorption of the water with chemical products is not recommended. Vacuum drying may be used. If there is any doubt about the cleanliness of the pipe it will be necessary to undertake a complete cleaning operation according to the procedure specified in 2.3.7.
6.4.7
Programme of Preventive Maintenance and Inspections

A programme of preventive maintenance shall be drafted. The type of programme will depend upon the installation and its particular characteristics. See 5.5. equipment to be inspected. inspection and maintenance tasks frequency of inspection and maintenance
6.5
Modifications
All modifications carried out on the system shall comply with the recommendations of 6.1 and 6.2. Selection of new equipment and the modified installations shall comply with the recommendations of parts 3, 4 and 5.
1982
Page 13 of 14
IGC
6.6
6.6.1
Withdrawal From, or Change of, Service

The withdrawal from or change of service of installations may involve work on them, which shall be carried out in accordance with the recommendations of 6.1 and 6.2 and the special instructions below.
6.6.2
Possible Cases
The taking of an installation out of service with the intention of returning it to service later. Removal of pipeline Changing from oxygen to another gas. Re-use for oxygen of a pipeline previously used for another gas or liquid.
6.6.2.1
Taking out of service The following shall be observed for any part of an installation that is taken out of service: The installation taken out of service shall be physically separated from the part remaining in service. Isolation by means of a valve or blind flange is not sufficient. The free end of the pipe withdrawn from service shall be fitted with an end cap. After purging, the installation shall be filled with dry, oil-free nitrogen or air, under slight positive pressure. During the period when it is out of service the installation shall continue to be inspected (5.5 and 6.4). In particular there shall be no relaxation of maintenance of cathodic protection. Before returning to service, the installation shall be subject to detailed inspection. (see 6.2). Removal of pipeline Before removal: The part retained shall be physically separated from the part to be demolished. The section to be removed shall be emptied and purged with air or nitrogen. Correct purging of dead end sections shall be assured. Changing from oxygen to another gas The installation shall be properly emptied and purged with air or nitrogen. The part of the installation to be re-used for another product shall be physically separated from the part remaining under oxygen. Isolation by means of a valve or blind flange is not sufficient. Change to oxygen service from another product Great care shall be taken when re-using a pipeline for service with oxygen. In order to determine the necessary action, a detailed survey of the installation shall be made. Collect all relevant documents Establish the history of the installation Determine general condition of the installation corrosion and wear internal condition of the pipe internal cleanliness of the pipe Examine the oxygen compatibility of the installation In many cases intensive cleaning will be necessary (see 2.3.0.3 and Table X). Nitrogen pipelines shall also be subjected to the above as it is possible for the nitrogen to have been compressed at some time by means of lubricated compressors, or with carbon piston rings. In the majority of cases, the components of the system will have to be replaced, or at the very least cleaned and adapted for oxygen use. The re-used part of the installation shall be physically separated from any part remaining. Isolation by means of a valve or blind flange is not sufficient. For commissioning see 6.2.
6.6.2.2
6.6.2.3
6.6.2.4
1982
Page 14 of 14
IGC
IGC 13/82 The Transportation and Distribution of Oxygen by Pipeline Part 7 : General Protection Preventive Means
The Transportation and Distribution of Oxygen by Pipeline Part 7 : General Protection Preventive Means
IGC 13/82/E
1982
Page 1 of 6
IGC
SECTION 7: GENERAL PROTECTION PREVENTIVE MEANS..............................................................3 7.1 LIGHTNING AND ELECTRICAL HAZARDS ...................................................................................................3 7.1.1 Protection Against Electrical Hazards ..............................................................................................3 7.1.2 Protection Against Lightning.............................................................................................................3 7.2 FIRE HAZARDS ..........................................................................................................................................3 7.2.1 The Danger of Outbreak of Fire. .......................................................................................................3 7.2.2 Fire Fighting Equipment ...................................................................................................................3
7.2.2.1 7.2.2.2 7.2.2.3 7.2.2.4 7.2.2.5 Means of protection incorporated in the installation ....................................................................................3 Fire extinguishers .........................................................................................................................................3 Water showers ..............................................................................................................................................4 Charging water extinguishers and showers...................................................................................................4 Fire hydrants.................................................................................................................................................4
7.2.3 Specific Recommendations ................................................................................................................4 7.2.4 Initial Action ......................................................................................................................................4 7.3 DANGERS OF OXYGEN ENRICHMENT ON PUBLIC PROPERTY .....................................................................4 7.4 THE DANGERS OF HYPOXIA ......................................................................................................................5 7.4.1 Breathing Equipment.........................................................................................................................5 7.4.2 Additional Emergency Equipment .....................................................................................................5 7.4.3 Specific Recommendations ................................................................................................................5 7.4.4 Initial Action ......................................................................................................................................5 7.4.5 First Aid for Hypoxia Victims............................................................................................................5 7.5 CRYOGENIC BURNS ...................................................................................................................................6 7.6 MAINTENANCE - LOCATION AND USE OF EMERGENCY AND FIRE-FIGHTING EQUIPMENT .........................6 7.7 INCIDENT REPORT .....................................................................................................................................6
1982
Page 2 of 6
IGC
SECTION 7: GENERAL PROTECTION PREVENTIVE MEANS

7.1
7.1.1
Lightning and Electrical Hazards

Protection Against Electrical Hazards
Electrical energy may be used on the stations for actuation of control equipment and lightning. Electrical installations shall comply with regulations regarding construction safety and protection of the workers. See 4.2.5.13 and 4.2.5.14.
7.1.2
Protection Against Lightning

For protection against lightning see 4.2.5.13. An exception may be made for valve stations situated at high altitudes in areas particularly subject to thunderstorms, for which it may, after consultation with experts, be decided to install a lightningarrester system:
7.2
7.2.1
Fire Hazards
The Danger of Outbreak of Fire.
Two specific causes of fire in an oxygen installation are: The internal ignition of oxygen circuits, described as spontaneous (1.3.1.7). Since its rapid development is practically impossible to stop, it is, therefore, advisable to vacate the area immediately. The fire may be confined once approach to take action is possible. Fires in an oxygen-enriched atmosphere should be dealt with in a traditional manner in view of the fact that the oxygen enrichment that favoured the start of the outbreak may vanish as the oxygen supply becomes exhausted.
7.2.2
7.2.2.1
Fire Fighting Equipment

Means of protection incorporated in the installation Safety devices actuated by lack of pressure and emergency stops strategically placed may be used to shut off the oxygen supply, vent to atmosphere and isolate power supply. Fire extinguishers Selection of fire extinguishing agents depends upon the material to be extinguished and in some cases upon the electrical environment. Fire-extinguishing agents suitable for an oxygen-enriched atmosphere are: water, powders with a sodium, calcium or potassium bicarbonate base, carbon dioxide and certain halogenated hydrocarbons such as bromochlordifluoromethane. Toxic products such as methyl bromide and chlorinated hydrocarbons shall not be used. For putting out clothing fires water extinguishers shall be used. Approved powder and CO2 extinguishers are suitable for fighting fires in electrical installations likely to remain live or in areas where the use of water as a fire-fighting agent is to be avoided. In the stations extinguishers shall be provided in adequate numbers and placed in carefully chosen, accessible places. In the absence of local regulations the number of portable extinguishers may be specified as follows: 1 extinguisher for a station floor area of up to 25 m2 2 extinguishers for 25 to 100 m2 3 extinguishers from 100 to 250 m2 4 extinguishers for over 250 m2 The numbers recommended apply to extinguishers of 8 to 10 litres capacity of water or equivalent quantities of fire-extinguishing agents.
7.2.2.2
1982
Page 3 of 6
IGC
During certain operations, in particular during work in trenches where there is a fire risk (see 6.1.2.7) one or two water extinguishers on wheels, with a capacity of the order of 50 litres, shall be provided for fighting clothing fires. 7.2.2.3 Water showers Where emergency water showers are used, supply from a permanent source is preferred or if this is not possible an independent system with a reserve of 150 to 200 litres of water and an adequate number of non-clogging spray nozzles. The nozzles shall be efficient and the total mean instantaneous delivery of water should be in the order of 150 to 200 1/min. Charging water extinguishers and showers Water extinguishers and showers operate by pressurisation with CO2 or Nitrogen. In the case of mobile extinguishers and safety showers specially designed for accidents to personnel, measures shall be taken to prevent freezing of the water. Fire hydrants In the case of large stations, a fire hydrant of the non-freezing type should be provided.
7.2.2.4
7.2.2.5
7.2.3
Specific Recommendations
The following recommendations shall be observed in order to prevent more serious consequences. It is dangerous to attempt to save a person who has caught fire in an oxygen enriched atmosphere by entering the area, because the rescuer will very probably also catch fire. No person who has been exposed to an oxygen-enriched atmosphere shall approach a source of ignition (cigarette, torch, sparks, etc). Personnel who have been exposed to an oxygen-enriched atmosphere shall ventilate clothing for at least 5 minutes, moving arms and legs to disperse the oxygen after loosening clothes. No attempt shall ever be made to extinguish a fire in an oxygen-enriched atmosphere by stifling it with the foot. This gesture could spread the fire and transfer it to be person concerned.
7.2.4
Initial Action
In case of fire, the following actions should be taken. The order will depend upon individual circumstances. Evaluate risk involved. Warn colleagues to leave the hazard area Operate emergency devices (emergency stop, isolation by valves, switching off current, etc) Inform the responsible persons and the emergency team where applicable. If necessary, inform the fire brigade and the police. Rope off the hazard area If clothing has caught fire, it is essential to extinguish the fire as quickly as possible - water is the most effective extinguishing agent. In the case of injury or burns to persons: Immediately call for medical assistance Strictly observe first aid instructions or those given by medical authorities.
7.3
Dangers of Oxygen Enrichment on Public Property

To avoid the danger of fire in an oxygen-enriched atmosphere, leakage of oxygen or flow from pipeline fractures shall be stopped or reduced as quickly as possible. Collaboration with the authorities concerned shall start immediately. The following actions shall be taken. The order will depend on individual circumstances. Leave the hazard area Operate emergency device (emergency stop, isolation by valves, switching off current, etc). Warn others and inform responsible persons and the emergency team where applicable. Inform the police and fire brigade Rope off the hazard area Prevent access by traffic into the hazard area (road, rail, rivers, etc).
1982
Page 4 of 6
IGC
7.4
7.4.1
The Dangers of Hypoxia

The dangers arising from hypoxia (lack of oxygen) have been dealt with in 1.3.4.
Breathing Equipment
When it is doubtful whether there is sufficient oxygen content in the atmosphere, breathing apparatus shall be used. The use of analytical instruments to monitor the atmosphere is recommended (see 6.1.2.2) Filter masks are useless in an atmosphere deficient in oxygen. The recommended types of breathing apparatus are as follows: the self contained type, using air cylinders may present difficulties in passing through restricted places. the fresh air mask, fed by means of a hose of adequate length and diameter. with a source of compressed air or from an area where the composition of the atmosphere is suitable for breathing. The mask shall have a valve system which prevents the user from breathing the same air indefinitely, which would rapidly cause asphyxia. The proper functioning of the valves shall be frequently checked. For resuscitation purposes, oxygen apparatus should be provided.
7.4.2
Additional Emergency Equipment

For work in confined areas or in trenches where there is a danger of oxygen deficiency means shall be provided to ensure quick and safe evacuation (e.g. safety harnesses with rope ladders, hoists if required).
7.4.3
Specific Recommendations
The following shall be observed to prevent more serious consequences. It is very dangerous to attempt to give assistance to a person in an oxygen-deficient environment without proper breathing apparatus. Without breathing equipment, the rescuer or the rescue team are in danger of suffering the same fate as the victim. The person giving assistance shall wear a harness and be under constant observation by a colleague who is out of the hazard area. Where possible resuscitation of the victim should be carried out outside the hazard area.
7.4.4
Initial Action
In the case of an oxygen-deficient atmosphere, the following action shall be taken. The order will depend upon individual circumstances: Recognise the problem Quickly identify the risks involved (see 7.4.2.) Organise the necessary evacuation and identify the hazard area If possible, isolate by means of valves or ventilate Take all action to avoid development of oxygen deficiency, or adopt the recommendation in 7.4.3. In the event of injury to persons: Inform the responsible persons and the rescue team where applicable Immediately call for medical assistance Strictly observe the first aid instructions or those given by medical authorities If necessary, take action according to 7.4.5.
7.4.5
First Aid for Hypoxia Victims

The following shall be carried out without delay: Remove victim from hazard area if possible - see 7.4.3. and keep victim warm. Administer oxygen if available or apply artifical respiration by one of the usual methods. Continue treatment until the patient regains consciousness or until a doctor decides to stop It is imperative to summon a doctor.
1982
Page 5 of 6
IGC
7.5
Cryogenic Burns
Cryogenic burns may occur if contact is made between skin and liquid nitrogen, oxygen or cold parts, whose temperature is around minus 190C. The treatment for cryogenic burns after return of the skin to normal temperature is the same as for normal burns. Safety gloves and glasses shall be worn when dealing with cryogenic liquids. The injured person shall be placed in the care of a doctor as soon as possible.
7.6
Maintenance - Location and Use of Emergency and Fire-Fighting Equipment

Fire-fighting and emergency equipment shall be maintained in perfect condition and located and kept in easily accessible positions. Personnel shall know its location and be trained in its use.
7.7
Incident Report
In the event of incident, a detailed analysis shall be made. Analysis of any incidents that occur provide useful information for the prevention of incidents, the selection of components and the solving of installation problems.
1982
Page 6 of 6

Igc 13 82

Uploaded by

Copyright:

Available Formats

Igc 13 82

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Igc 13 82

Uploaded by

Copyright:

Available Formats

IGC

Industrial Gases Committee

Recommendations for the Design, Construction, Operation and Maintenance

Reproduced in IMSS with permission

Industrial Gases Committee

1.1.4.1 1.1.4.2 1.1.4.3 1.1.4.4

1.2.2.1 1.2.2.2 1.2.2.3 1.2.2.4 1.2.2.5

1.3.1.6.1 1.3.1.6.2 1.3.1.6.3 1.3.1.6.4 1.3.1.6.5 1.3.1.6.6 1.3.1.6.7

Safety limits of oxygen concentrations........................................................................................................20

Reproduced in IMSS with permission

Industrial Gases Committee

Combustion and Explosion of Gases and Vapours..................................................................................... 20

1.3.3.3.1 1.3.3.3.2 1.3.3.3.3 1.3.3.3.4 1.3.3.3.5

Influencing Factors ......................................................................................................................................23

1.3.3.4.1 1.3.3.4.2 1.3.3.4.3 1.3.3.4.4

1.3.4.1 1.3.4.2 1.3.4.3 1.3.4.4

1.4.2.1.1 1.4.2.1.2 1.4.2.1.3 1.4.2.1.4 1.4.2.1.5 1.4.2.1.6 1.4.2.1.7

External Causes of Accidents......................................................................................................................... 31

1.4.4.1 1.4.4.2 1.4.4.3 1.4.4.4 1.4.4.5

1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 1.4.11 1.4.12

Industrial Gases Committee

Reproduced in IMSS with permission

Industrial Gases Committee

Reproduced in IMSS with permission

Industrial Gases Committee

Reproduced in IMSS with permission

Industrial Gases Committee

Reproduced in IMSS with permission

Industrial Gases Committee

Reproduced in IMSS with permission

Industrial Gases Committee

1.1.3.7 1.1.3.8 1.1.3.9

Reproduced in IMSS with permission

Industrial Gases Committee

-183C 1.141 kg/1

Reproduced in IMSS with permission

Industrial Gases Committee

Reproduced in IMSS with permission

Industrial Gases Committee

Flammability of Materials and Products in Oxygen

Reproduced in IMSS with permission

Industrial Gases Committee

Reproduced in IMSS with permission

Industrial Gases Committee

Figure 3 : Ignition temperatures and combustion rates as a function of pressure

Reproduced in IMSS with permission

Industrial Gases Committee

Figure 4 : Ignition as a function of velocity, pressure and temperature

Reproduced in IMSS with permission

Industrial Gases Committee

Reproduced in IMSS with permission

Industrial Gases Committee

Reproduced in IMSS with permission

Industrial Gases Committee

Table 1 : Oxygen Installations conditions for ignition and its effects

Reproduced in IMSS with permission

Industrial Gases Committee

Ignition in an Oxygen-Enriched Atmosphere

Reproduced in IMSS with permission